Navy Manufacturing Technology Project S2306 National Shipbuilding Research Program All Panel Meeting March 2015 John Mazurowski Electro-Optics Manufacturing Technology Center DISTRIBUTION STATEMENT A: Approved for public release. 1
Technology Discussion This project has developed a cable test system that incorporates all cable media types- power, communications, digital, coaxial, and fiber optic. Integrated Link Test System (ILTS) Paradigm Manual link-to-link tests take time / multiple personnel. Test results are handwritten and contain many transcription / hookup errors. ILTS coordinates testing and stores test results automatically. MRP database contains cable data, acceptance criteria, test results, and certification record. Networked communication between database / system / remote test units. 2
Project Team 3
Project Team ONR ManTech COMPANY Penn State EOC HII Newport News DIT-MCO International General Dynamics Land Systems Richard Henson TELEPHONE David Ditto, John Mazurowski, Lucas Cashdollar, Melissa McCandless Dave Gruszkowski, Vannia Willis, Lisa Maddrey, NP Rao, Jason Jaques, Billy Marshall, Steve Harbick, Gordon Burr, Bob Smole, Mark Dunford John Kusek, Gregg Carder, Charlie Jennings, Mike Reed, TJ Surgeon, Kurt Morrison Steve Spurlin, Eric Clore, Greg Bagwell 4
Project Description Participants and Roles Penn State Electro-Optics Center- Project Management and Systems Engineering Huntington Ingalls Newport News- End User PMS 450- Program Representative NSWCDD- Technical Warrant Holder DIT-MCO International- System Supplier General Dynamics Land Systems- System Designer Technical Deliverables Monthly Spend Plan, Project Schedule, Monthly Reports, EVM Report Technology Transition Plan, Risk Assessment Final Report, Demonstration Period of Performance June 2010 June 2015 5
ILTS System Features Primary Customer: PMS 450 Virginia Class Submarine Requirements: Must fit through 30 inch opening. Processor / Electrical: 16 in x 15 in x 5 in. RF: (Agilent 9918A): 12 in x 7 in x 3 in. Fiber Optic: 18 in x 13 in x 7 in. Weight < 25 pounds. Processor: 18 pounds. RF Unit: 6.6 pounds. Fiber Optic: 10 pounds. MRP database stores requirements and test data. Communications complies with Information Systems policies. Compliance with military test equipment specification (Mil-PRF-28800 Class 2). 6
Benefits: ILTS System Features In shipbuilding, deck access time is valuable and highly choreographed. ILTS measurement setup is done offline in order to minimize deck access. ILTS modular design supports electrical, RF, and fiber optic cable measurements in accordance with recognized standards. ILTS is portable; hot-swappable batteries last >1 shift each. The ILTS supports a baseline MRP / EDA system, and can be adapted to others. ILTS system suppliers form the ILTS supply chain to provide downstream support. BASELINE Electrical continuity 100 pin x 3 Electrical isolation 100 pin x 3 RF insertion loss to 26 GHz RF return loss / VSWR to 26 GHz Fiber Optic insertion loss SM / MM Fiber Optic return loss SM OPTIONAL DC voltage to 600 volts AC voltage to 500 volts Resistance to 50 megohm Capacitance to 100 microfarad Time Domain Reflectometry (Electrical) 200 MHz Oscilloscope 7
ILTS System Integration External Network (ILTS Portable Test System) HII Domain (ILTS Central Database Manager) ILTS Portable Test System ILTS Tablet Network Node HII Web Service HII DB Server ILTS Analyzer FIREWALL HII Domain Computer Optical Module RF Module 8
ILTS Supply Chain CUSTOMER REQUIREMENTS BASELINE SYSTEM BASIC FEATURES GDLS ILTS SYSTEM SUPPLIER DIT-MCO ADAPTERS NEW FUNCTIONS DATA STRUCTURES 9
Metrics PARAMETER BASELINE GOAL CURRENT Cost Metric: VCS Cable Measurements 36,000 Hours 28,800 Hours 36,000 Hours Performance Metric: Requirements Defined 0% 376 (100%) 534 (>100%) Performance Metric: Verification Complete 0% 534/534 (100%) 520/534 (97%) Estimated cost avoidance 7200 hours X $65/hour = $468,000 per hull. The project goal is a reduction in labor connected with cable measurement and fault diagnosis. 10
Progress Administrative Progress: Award received from ONR June 2010 Subcontract awarded October 2011 Technology Transition Plan submitted May 2012 Task 2.1 2.4 complete June 2012 Task 2.5 Test System Supplier identified and PO placed January 2013 Weekly teleconferences begun May 2013 Review meeting and requirements review (PDR) June 2013 Task 2.5 2.12 complete July 2014 System requirements verification (CDR) July 2014 Technology Transition Plan update submitted July 2014 System demonstration August 2014 Final Review December 2014 Technical Progress: Requirements and Specification June 2012 Requirements reviewed June 2013 Design activities begun July 2013 Preliminary design review August 2013 Critical design review July 2014 System demonstration August 2014 Software task list finalized November 2014 Risk and Mitigation: Risk assessment completed each review in accordance with Navy ManTech guidance. 11
Project Schedule 12
Transition TRANSITION STRATEGY: Documented in ManTech Technology Transition Plan (TTP), submitted May 2012 and updated July 2014. IMPLEMENTING ORGANIZATION: Ingalls Shipbuilding Newport News. SUPPLY CHAIN: Future product of DIT-MCO International and General Dynamics Land Systems. FUNDING SOURCES: Ingalls Shipbuilding Newport News transition funding ($50K) and capital acquisition ($50K). In-Kind: RF network analyzer. DEMONSTRATION: System verification held July 15-17 at GDLS. System demonstration August 2014 aboard future SSN 785 USS John Warner. 13
Related Projects PROJECTS: NAVAIR N00421-03-D-0044 Fiber Optic Network Development NSWC Crane N00164-09-C-GR34 Task V Copper Replacement COLLABORATIVE INTERACTIONS: Army Stryker Vehicle- General Dynamics Land Systems National Shipbuilding Research Program Flexible Interface for Automated Circuit Tester INDUSTRY: HII-NNS ACCS System DIT-MCO International internal product development for air platforms 14
Future Actions Close software task list. Integration of ILTS into HII-NNS shipyard. Future: Adapt for use at other shipyards / platforms. Future: Merge functionality with ship cabling EDA tool. Future: Enhance fiber optic measurement function. 15
Jointness 16
Acknowledgements This material was supported by the Office of Naval Research under contract N00014-05-D-0275 / 0002. Any opinions, findings, conclusions, or recommendations expressed in this presentation are those of the authors and do not necessarily reflect the views of the Office of Naval Research. 17