6 mai 2019 | International, Naval

Robots and Lasers Are Bringing Shipbuilding into the Digital Age

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.”

https://www.defenseone.com/technology/2019/05/robots-and-lasers-are-bringing-shipbuilding-digital-age/156763/

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  • Contract Awards by US Department of Defense - September 10, 2019

    11 septembre 2019 | International, Aérospatial, Naval, Terrestre, C4ISR, Sécurité

    Contract Awards by US Department of Defense - September 10, 2019

    NAVY Collins Aerospace, Cedar Rapids, Iowa, is awarded a $310,509,144 modification (P00009) to a previously awarded firm-fixed-price contract (N00421-18-D-0004). This modification exercises an option for the procurement of AN/ARC-210(v) radios for installation in over 400 strategic and tactical airborne, seaborne and land based (mobile and fixed) platforms for the Navy, Marine Corps, Army, Coast Guard, other government agencies and foreign military sales customers. Work will be performed in Cedar Rapids, Iowa, with deliveries expected to be completed in September 2022. No funds are being obligated at time of award; funds will be obligated on individual delivery orders as they are issued. The Naval Air Systems Command, Patuxent River, Maryland, is the contracting activity. ViaSat Inc., of Carlsbad, California, is awarded a $100,465,034 modification to its current indefinite-delivery/indefinite-quantity contract (N00039-15-D-0008) to increase the ceiling of the existing production contract line item number (CLIN), and the systems engineering and integration CLIN of the referenced contract. This ceiling increase will implement the capabilities identified in the Joint Requirements Oversight Council (JROC) memorandum dated Aug. 20, 2018, wherein the JROC endorsed the advanced capabilities of Concurrent Mutli-Netting-4 (CMN-4), Concurrent Contention Receive and Enhanced Throughput as the Department of Defense baseline for all future upgrades to any platform requiring Link-16 tactical data links. In response to the JROC memorandum, current Link-16 platform users identified the need for the procurement and/or retrofit of 3,370 additional Multifunctional Information Distribution System Joint Tactical Radio System (MIDS JTRS) CMN-4, F-22 Raptor, Tactical Targeting Network Technology terminals. This increase in scope will be in addition to the current scope in the original Class Justification and Approval (CJ&A) No. 17,226 approved April 25, 2014, for the MIDS JTRS, the amended CJ&A No. 18,012 approved Jan. 18, 2017, for the addition of the MIDS JTRS TTNT development effort, CJ&A No. 18,415 approved Sept. 11, 2018, for the addition of MIDS Modernization Increment 2, retrofits, and additional MIDS JTRS terminals, not including F-22s, and the initial CJ&A 19,415 approved July 2, 2019, to implement the JROC memorandum as described above. The modification will increase the contract value to $889,465,034. This contract combines purchases for the Navy, Air Force and MIDS Program Office, as well as to the governments of Austria, Chile, Finland, Israel, Jordan, Japan, Kuwait, Malaysia, Morocco, Oman, Pakistan, Qatar, South Korea, Saudi Arabia, Singapore, Sweden, Switzerland, Taiwan, Thailand, United Arab Emirates, Australia, Canada, New Zealand and the United Kingdom. This contract also includes purchases to NATO and all NATO nations under the Foreign Military Sales program. Work will be performed in Carlsbad, California, and is expected to be completed May 2020. No additional funding will be placed on contract or obligated at the time of modification award. Existing contract funds will not expire at the end of the current fiscal year. Future contract actions will be issued and funds obligated as individual delivery orders. This contract modification was not competitively procured because it is a follow on, sole source, multiple award procurement pursuant to the authority of Title 10 U.S. Code 2304(c)(1): only one or a limited number of responsible sources (Federal Acquisition Regulation subpart 6.302-1(a)(2)). Non-competitive procedures were approved for this modification under CJ&A 19,415. Naval Information Warfare System Command, San Diego, California, is the contracting activity. Siemens Government Technologies Inc., Arlington, Virginia, is awarded a firm-fixed-price modification of $46,677,053 to increase the maximum dollar value of a task order (N39430-18-F-9924) for energy improvements at Naval Air Station Sigonella, Naval Station Rota and Naval Support Activity Naples. The total cumulative value of the contract is $218,220,667. Work will be performed in Naples, Italy (50%); Sigonella, Italy (30%); and Rota, Spain (20%), and is expected to be completed October 2041. The work provides for design and installation of the following energy conservation measures: boiler plants, chiller systems, motors, water and lighting improvements. The work also provides for performance period services consisting of measurement and verification, operations and maintenance, and repair and replacement services. No funds will be obligated with this award, as private financing obtained by the contractor will be used for the construction phase. The Naval Facilities Engineering and Expeditionary Warfare Center, Port Hueneme, California, is the contracting activity. Data Link Solutions LLC, Cedar Rapids, Iowa, is awarded a $30,000,000 modification to its current indefinite-delivery/indefinite-quantity contract (N00039-15-D-0007) to increase the ceiling of the existing systems engineering and integration contract line item number (CLIN) of the referenced contract. This ceiling increase will implement the capabilities identified in the Joint Requirements Oversight Council (JROC) memorandum dated Aug. 20, 2018, wherein the JROC endorsed the advanced capabilities of Concurrent Mutli-Netting-4 (CMN-4), Concurrent Contention Receive and Enhanced Throughput as the Department of Defense baseline for all future upgrades to any platform requiring Link-16 tactical data links. In response to the JROC memorandum, current Link-16 platform users identified the need for the procurement and/or retrofit of 3,370 additional Multifunctional Information Distribution System Joint Tactical Radio System (MIDS JTRS) CMN-4, F-22 Falcon, Tactical Targeting Network Technology (TTNT) terminals. This increase in scope will be in addition to the current scope in the original Class Justification and Approval (CJ&A) No. 17,226 approved April 25, 2014, for the MIDS JTRS, the amended CJ&A No. 18,012 approved Jan. 18, 2017, for the addition of the MIDS JTRS TTNT development effort, CJ&A No. 18,415 approved Sept. 11, 2018, for the addition of MIDS Modernization Increment 2, retrofits and additional MIDS JTRS terminals, not including F-22s, and the initial CJ&A 19,415 approved July 2, 2019, to implement the JROC memorandum as described above. The contract covers the production, development and sustainment of the MIDS JTRS terminals. The modification will increase the contract value to $1,254,529,670. This contract combines purchases for the Navy, Air Force and MIDS Program Office, as well as to the governments of Austria, Chile, Finland, Israel, Jordan, Japan, Kuwait, Malaysia, Morocco, Oman, Pakistan, Qatar, South Korea, Saudi Arabia, Singapore, Sweden, Switzerland, Taiwan, Thailand, United Arab Emirates, Australia, Canada, New Zealand and the United Kingdom. This contract also includes purchases to NATO and all NATO nations under the Foreign Military Sales program. Work will be performed in Cedar Rapids, Iowa (50%); and Wayne, New Jersey (50%), and is expected to be completed June 2020. No additional funding will be placed on contract or obligated at the time of modification award. Existing contract funds will not expire at the end of the current fiscal year. Future contract actions will be issued, and funds obligated as individual delivery orders. This contract modification was not competitively procured because it is a follow-on sole-source, multiple-award procurement pursuant to the authority of Title 10 U.S. Code 2304(c)(1): only one or a limited number of responsible sources (Federal Acquisition Regulation subpart 6.302-1(a)(2)). Non-competitive procedures were approved for this modification under CJ&A 19,415. Naval Information Warfare System Command, San Diego, California, is the contracting activity. ' Simmonds Precision Products, Vergennes, Vermont, is awarded a $12,986,404 cost-plus-fixed-fee contract for the "Low Cost Air-Drop Munition Weapon System Development Program." Work will be performed in Simmonds Precision Products, Vergennes, Vermont (58%); Aerojet Rocketdyne Inc., Rancho Cordova, California (19%); Developmental & Demonstration Testing Facilities (to be determined) (11%); Systima Technologies Inc., Kirkland, Washington (6%); Moog Inc., Elma, New York (5%); and National Technical Systems Boxborough, Boxborough, Massachusetts (1%), and is expected to be completed February 2021. Fiscal 2018 research, development, test and evaluation (Navy) funds for $8,208,343 will be obligated at time of award, none of which will expire at end of current fiscal year. This contract was competitively procured under N00014-19-S-B001, long range broad agency announcement (BAA) for Navy and Marine Corps Science and Technology. Since proposals will be received throughout the year under the long range BAA, the number of proposals received in response to the solicitation is unknown. The Office of Naval Research, Arlington, Virginia, is the contracting activity (N00014-19-C-1062). Booz Allen Hamilton Inc., McLean, Virginia, is awarded an $11,765,526 time and material modification to exercise Option Period One under a previously awarded contract N00189-18-F-Z362. The work provides financial improvement and audit readiness support services to the Deputy Commandant, Programs and Resources, to address OMB A-123 governance, audit response coordination and audit coaching. After award, this contract was transferred to the Marine Corps Installations Command Headquarters, Contracting Office, and was assigned a new contract number M95494-19-F-0032. Work will be performed in Arlington, Virginia (75%); and Quantico, Virginia (25%), and is expected to be completed September 2020. Fiscal 2019 operation and maintenance (Marine Corps) funds for $1,527,843 will be obligated at the time of award and will expire at the end of the current fiscal year. 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