The CAD, PDM and PLM challenges and how CERN solved them.

2. Michal Mlynarčík
Designing & building the world’s
largest machine
European Organization for Nuclear Research
September 2013
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3. Agenda
1.
2.
3.
4.
5.
6.
CERN and the LHC accelerator complex
Our PLM challenges
CERN EDMS – our PLM platform
Our CAD challenges
CATIA/SmarTeam – our CAD/PDM platform
On-going efforts & Conclusions
September 2013
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4. About CERN
• CERN is the world’s largest particle physics centre.
• Founded in 1954, CERN was one of Europe’s first joint ventures and has
today 20 member states and 6 observer states (incl. US & Japan).
• CERN provides scientists from all around the world with tools to study the
building blocks of matter and the forces that hold them together.
• This is done with huge particle accelerators based on cutting edge
technologies.
• People: ~2.350 staff, ~2.000 contractors and ~10.000 visiting scientists.
• Annual budget: ~725 million Euros
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5. About CERN
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6. About CERN
CR: 194
SR: 58
251 Czech nationals
133 Slovak nationals
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7. CERN – Facts and fiction
• Seeking answers to question about the Universe also advances the frontiers
of technology.
• The World Wide Web was invented at CERN in 1989 by the British scientist
Tim Berners-Lee.
• Many other spin-offs: Improved cancer therapy technology, medical and
industrial imaging, radiation processing, electronics, measuring
instruments, new manufacturing processes and materials,..
• CERN unfortunately does not own an X-33 aircraft as it was suggested in
Dan Brown’s book “Angels and Demons”. But we do create anti-matter….
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8. The LHC – our flagship accelerator
•
The Large Hadron Collider (LHC)
consists of millions of high-tech
components that are installed in a 27
km long circular tunnel, 100 meters
below ground.
•
Many of these very expensive
components will have to be maintained
and individually traced for 20-25 years
in a partly radioactive environment.
•
The LHC is the result of an international
collaboration involving academic
institutes and industries from >80
countries.
•
Material cost: ~ 4.7 billion Euros
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9. The LHC accelerator
Bigger is better if you’re searching for the smaller.
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10. The LHC accelerator
Bigger is better if you’re searching for the smaller.
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11. The LHC accelerator
Bigger is better if you’re searching for the smaller.
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12. ATLAS – one of four LHC detectors
The physics is difficult. The engineering is next to impossible.
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13. ATLAS – one of four LHC detectors
The physics is difficult. The engineering is next to impossible.
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14. ATLAS – one of four LHC detectors
The physics is difficult. The engineering is next to impossible.
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15. The LHC accelerator complex...
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16. The LHC accelerator complex...
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17. Agenda
1.
2.
3.
4.
5.
6.
CERN and the LHC accelerator complex
Our PLM challenges
CERN EDMS – our PLM platform
Our CAD challenges
CATIA/SmarTeam – our CAD/PDM platform
On-going efforts & Conclusions
September 2013
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18. Our PLM challenges
Very long lifecycles and need for internal knowledge transfer.
Our installations have lifecycles of more than 50 years. One generation
will build the accelerators – the next will operate and maintain it.
Design
Manufacturing
Dismantling
CERN
EDMS
Installation
Maintenance
Commissioning
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19. Our PLM challenges: Complexity
• Large, complex and technically advanced.
– The accelerator complex consists
of some 100 million assets.
– Most are unique and the
result of many years of R&D.
– A cryogenics example to illustrate the technical complexity:
• A total LHC cold mass of 37,500 tons is cooled down to 1.9 K (-271 ̊C)
in order to enable superconducting magnets to bend and focus
proton beams.
• Cooling medium: 140 tons of super fluid helium
CERN’s helium inventory corresponds to 2% of the EU market.
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20. Our PLM challenges: Quality
• Quality and control versus
innovation and creativity
– µm tolerances and kilometer
long beam lines.
– 40,000 leak-tight welds keeping
700,000 liters of liquid helium in
place.
– Components are in many cases
not accessible once installed
- like in satellites!
– Easier said than done
- especially in a scientific environment!
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21. Our PLM challenges: Maintenance
• A chain of accelerators and interrelated systems.
– The availability of the accelerator complex depends on the availability
of the whole chain of injectors and accelerators – some of which are
already 50 years old.
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22. Our PLM challenges: Operation
• Some major operational constraints.
– Energy consumption: a town of 150,000
inhabitants (250 MW at peak periods)
– Operation between shutdowns : ~1.5 years
– Warm-up and cool-down period: 3+3 weeks
4 major breakdowns during operation
means no physics that year!
• Regulations for nuclear installations.
– LHC is classified as a nuclear installation
which requires strict traceability of equipment,
detailed logs of technical interventions and well
documented procedures.
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23. Agenda
1.
2.
3.
4.
5.
6.
CERN and the LHC accelerator complex
Our PLM challenges
CERN EDMS – our PLM platform
Our CAD challenges
CATIA/SmarTeam – our CAD/PDM platform
On-going efforts & Conclusions
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24. The CERN EDMS – our PLM platform
• CERN’s integrated PLM platform is called the CERN Engineering &
Equipment Data Management System .
• PLM at CERN is consequently not equal to one single system but a set of
interfaced applications with several commercial systems as its main pillars.
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25. Overview of the CERN EDMS
Documents & Components:
~2.500.000 documents & components stored
~6.300 new document & drawings per month
~2,000,000 interventions logged
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Users:
~5.400 registered active users
~120.000 file downloads per month
~8.000 support requests per year
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26. CATIA/Smarteam & the CERN EDMS
integration
Data publishing
- Published by designer or after reaching
state of certain maturity
Workflows
- Approval and release workflows,
versioning rules and access control
Viewing of published data
- Integrated 3D and 2D viewing in EDMS
Archiving
- Long term archiving of drawings
Accessibility
- Fully web-based environment
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27. CATIA/Smarteam & the CERN EDMS
integration
Data publishing
- Published by designer or after reaching
state of certain maturity
Workflows
- Approval and release workflows,
versioning rules and access control
Viewing of published data
- Integrated 3D and 2D viewing in EDMS
Archiving
- Long term archiving of drawings
Accessibility
- Fully web-based environment
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28. CATIA/Smarteam & the CERN EDMS
integration
Data publishing
- Published by designer or after reaching
state of certain maturity
Workflows
- Approval and release workflows,
versioning rules and access control
Viewing of published data
- Integrated 3D and 2D viewing in EDMS
Archiving
- Long term archiving of drawings
Accessibility
- Fully web-based environment
September 2013
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29. CATIA/Smarteam & the CERN EDMS
integration
Data publishing
- Published by designer or after reaching
state of certain maturity
Workflows
- Approval and release workflows,
versioning rules and access control
Viewing of published data
- Integrated 3D and 2D viewing in EDMS
Archiving
- Long term archiving of drawings
Accessibility
- Fully web-based environment
September 2013
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30. CATIA/Smarteam & the CERN EDMS
integration
Data publishing
- Published by designer or after reaching
state of certain maturity
Workflows
- Approval and release workflows,
versioning rules and access control
Viewing of published data
- Integrated 3D and 2D viewing in EDMS
Archiving
- Long term archiving of drawings
Accessibility
- Fully web-based environment
September 2013
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31. Agenda
1.
2.
3.
4.
5.
6.
CERN and the LHC accelerator complex
Our PLM challenges
CERN EDMS – our PLM platform
Our CAD challenges
CATIA/SmarTeam – our CAD/PDM platform
On-going efforts & Conclusions
September 2013
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32. Specific CAD challenges at CERN
• Micrometer precision models
assembled in installations ranging
over several kilometers.
• Multidisciplinary environment.
• Large international collaborations
with an extreme multi-CAD
environment.
(At LHC project start-up some 20 different tools
were identified!)
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33. Precision
Micrometer precision for RF structures ...
-Export to stress analysis tools and for machining
... in instalations ranging over several km.
-Multilevel skeleton models with local coordinates
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34. Precision
Micrometer precision for RF structures ...
-Export to stress analysis tools and for machining
... in instalations ranging over several km.
-Multilevel skeleton models with local coordinates
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35. Precision
Micrometer precision for RF structures ...
-Export to stress analysis tools and for machining
... in instalations ranging over several km.
-Multilevel skeleton models with local coordinates
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36. Precision
Micrometer precision for RF structures ...
-Export to stress analysis tools and for machining
... in instalations ranging over several km.
-Multilevel skeleton models with local coordinates
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37. Precision
Micrometer precision for RF structures ...
-Export to stress analysis tools and for machining
... in instalations ranging over several km.
-Multilevel skeleton models with local coordinates
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38. Multidisciplinary environment
Civil Engineering
Metallic Structures
CATIA V5 used by various disciplines
Cooling & Ventilation
Power Devices
Accelerator &
Mechanical Equipments
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Radio Frequency
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39. International collaboration
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40. Agenda
1.
2.
3.
4.
5.
6.
CERN and the LHC accelerator complex
Our PLM challenges
CERN EDMS – our PLM platform
Our CAD challenges
CATIA/SmarTeam – our CAD/PDM platform
On-going efforts & Conclusions
September 2013
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41. • CATIA was bought at CERN in 2003 to replace Euclid.
• After a first CATIA pilot project, the system has been since 2005 in
production, and full speed since 2007.
• Euclid was permanently stopped at CERN in Dec 2008 after an
intense migration period ~500 man-years of design work migrated.
• CATIA is today the only official and centrally supported 3D CAD tool
at CERN with ~250 users.
1983
2003
1993
Euclid
Dec. 2008
Euclid 3
CATIA
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42. CATIA/SmarTeam at CERN
Current version and upgrade plan
Current release of CATIA/SmarTeam:
Next release to upgrade to:
Target date for upgrade:
Current Implementation
One CAD system for all (at CERN):
PDM with strong CAD integration:
Item Centric approach:
Domain
Data management in
CATIA/SmarTeam
September 2013
R20
R23
October 2013
CATIA V5
SmarTeam
SmarTeam & EDMS
Specific modules
Tool
CAD data management
Item management
BOM data management
CATIA/SmT integration
BOM Compare tool
CartWeb tool
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43. CAD management
Marec 2011
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44. CAD management
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45. CAD management
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46. CAD management
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47. CAD management
CATProduct 1
CATProduct 2
CATPart 1
CATPart 2
CATPart 3
CATProduct 3
CATPart 4
CATPart 5
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48. CAD management
CATProduct 1
CATProduct 2
CATPart 1
CATPart 2
CATPart 3
CATProduct 3
CATPart 4
CATPart 5
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49. Item Management
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50. Item Management
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51. Item Management
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52. Item Management
CATProduct 1
CATProduct 2
CATPart 1
CATPart 2
CATPart 3
CATProduct 3
CATPart 4
CATPart 5
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53. Item Management
Assembly 1
Sub-assembly 1
Part 1
Part 2 x 2
Part 3
Sub-assembly 2
Part 4
Part 5
Marec 2011
CATProduct 1
CATProduct 2
CATPart 1
CATPart 2
CATPart 3
CATProduct 3
CATPart 4
CATPart 5
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54. Item Management
Assembly 1
Sub-assembly 1
Part 1
Part 2 x 2
Part 3
Sub-assembly 2
Part 4
Part 5
Glue
Marec 2011
CATProduct 1
CATProduct 2
CATPart 1
CATPart 2
CATPart 3
CATProduct 3
CATPart 4
CATPart 5
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55. BOM management
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56. BOM management
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57. BOM management
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58. BOM management
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59. CATIA SmarTeam Demo
You can watch demo videos demonstrating CATIA SmarTeam BOM item management at CERN and more on my media channel:
http://vimeo.com/michalmlynarcik
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60. Agenda
1.
2.
3.
4.
5.
6.
CERN and the LHC accelerator complex
Our PLM challenges
CERN EDMS – our PLM platform
CATIA/Smarteam integration
CATIA/SmarTeam – our CAD/PDM platform
On-going efforts & Conclusions
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61. Recent and on-going projects
•
Integration of SmarTeam with Oracle Agile e6
CERN is currently in the process of integrating
our PDM SmarTeam with the corporate PLM
Agile e6 from Oracle.
•
Free public 3D CAD viewing
In order to visualize and evaluate the 3D data
outside PDM, users can download data
converted to the 3DVIA Composer format and
open it with the free 3DVIA Composer Player
•
Offline EDMS viewer
With a new CERN-developed offline viewer,
maintenance technicians can browse
documents in the field on a laptop instead of
large paper folders.
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62. Recent and on-going projects
•
Strong focus put on Item management
– Moved from a document-centric to an itemcentric approach in the design offices.
– Equipment groups are documenting their
equipment using BOMs and technical data.
– Increased efforts in the traceability of material
compositions for radioactive waste purposes.
•
Documenting the existing machines
– EDMS has proven very useful for the LHC, now
the already existing machines are being
documented in the same standardized manner
using the same tools.
– This also means scanning both paper drawings
and microfilm.
– Items and documents are registered for 50 years
old machines and installations.
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63. Conclusions
Our current strategy:
A local PDM for the design offices and a
global PLM for the whole organization.
3DVIA Composer suite of software proved to be valuable asset
-
The 3DVIA Enterprise batch translation publishes the 3D data to the PLM on demand
The 3DVIA Composer Player is a freely available software which allows users to view
and evaluate the published data
SmarTeam became the work horse of the CERN CAD
-
It enabled to us concentrate on further enhancements and integration with the PLM
system
The future of SmarTeam is counted, but so long we haven't been able to identify the
successor
Dassault will one day replace CATIA V5 and SmarTeam with V6
-
Our current evaluation of CATIA V6 proved to be not conclusive
Will our current strategy remain valid with two full-fledge PLM systems available?
What is the license strategy of Dassult Systémes concerning the research branch?
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64. Conclusions
Where are the long-term savings for CERN?
–
–
The integrated PDM platform has forced engineering groups to follow
common working methods.
The collaborative environment of SmarTeam allowed designers work
on complex engineering tasks in a highly diverse and volatile setting of
CERN
Keys to success for the PDM implementation at CERN;
–
–
–
–
•
A global plan and strong management support.
A support and consulting team working closely with the user groups.
A significant training campaign – over 500 people have been trained.
A long-term vision – the PDM project at CERN started 1993
Implementing PDM in a scientific environment is possible and
is an absolute must for a laboratory like CERN.
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1-day
2-day
Introduction
course
Administration
course
1-day
1-day
Introduction
course
Engineering
course
½ -day
MTF
course
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65. e-mail: Ing.Michal.Mlynarcik@gmail.com