Power Tools 1993 November

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submit SOLIDMOD (NewWave Write) Solid Modeling at Hewlett Packard: Methods & Benefits by Peter Zivkov Corporate Engineering Hewlett Packard May 20 1992 * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * Please note that Peter's primary responsibility is to * * improve HP's INTERNAL engineering productivity. This * * includes supporting HP's 2000 ME CAD users, so he * * does not have time to respond to requests from the * * field. Instead, the field should continue to use the * * HP divisions' sales centers for information. * * * * Thank you, -Sue Perry, WSBU ME Market Segment Manager * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * Abstract: HP has successfully employed solid modeling & CAD/CAM technology on a broad scale for its product development. By taking advantage of its own workstation and CAD technology and overcoming some of the limitations of 3d solids with innovative engineering processes, HP has been able to develop new products of higher quality, at lower cost, in about half of the traditional time. This article describes the methods of use and benefits of solid modeling which have helped HP to improve its own mechanical engineering productivity. ---- MECHANICAL ENGINEERING AT HP TODAY Hewlett Packard is a leading producer of engineering workstations and MCAE tools for mechanical engineering. Because of this, HP's own product development efforts rely heavily on the effective use of solid modeling technology. Through the use of solids, HP has been able to develop its new products of higher quality, at lower cost, in a shorter time than ever before. There are about 2000 ME CAD seats installed at Hewlett Packard. Three quarters of these seats are HP's ME30 solid modeling systems, while the rest are HP's ME10 2D drafting systems. These systems and the people using them are distributed over more than 70 sites world-wide. All of them are linked through HP Internet, one of the world's largest privately-operated computer networks. Since most of its divisions have to share and exchange engineering data to develop new products, HP has chosen ME10 and ME30 as a standard CAD tool across the company. As we'll see later, this was an important first step in attaining benefits from the use of solid modeling in downstream processes like drafting, analysis, and manufacturing. The benefits described below have been an important factor in improving HP's competitiveness and time to market capability. During the last 5 years, HP has been making some significant and very important transitions: - from paper-based information to electronic information & processes - from serial to concurrent engineering practices - from hardware prototypes to software models and tools - from paper and pencils to engineering workstations - from individual productivity efforts to automating the workgroup These changes are by no means complete, but there have been enormous improvements in HP's mechanical engineering process during the last few years. Let's now look at the product development cycle and see how HP takes advantage of solids during each phase of product development... DESIGN More than two thirds of HP's new design data is being created using our ME30 solid modeling systems. This is an unusually high percentage for any company, let alone for a company of HP's size. How did HP get to this point? Here are some of the reasons HP was able to adopt solids so successfully: Standard design tools HP engineers & managers consciously chose to standardize on one 2d and 3d design tool, HP's ME10 and ME30, for every one of HP's divisions. Without this early decision, it would have been impossible to take full advantage of solids in design or to integrate other computer tools, like FEA or CAM, in a uniform way across the entire corporation. Interactivity and visualization In addition to the use of a standard solid modeling tool for the entire company, HP has also employed the use of graphics accelerator hardware to quickly display even very complex solid models allowing engineers to work constantly with a complete shaded 3d model, making visualization and design much more intuitive and productive. Figure 1 show a typical example of ME30 and the kind of models one can see at HP. The result of using 3d models is an immediate understanding of the design by all people on the product development team (even managers!). With 3d shaded solids, the design engineer can quickly understand a new design, identify errors, and improve the quality of the design by merely altering the computer model. Better engineering tools, like solid modeling, simplify communication among the product development team on large or complex projects. Some of the projects which are currently underway at HP today could not be conceived or attempted without the successful use of solid modeling. Figure 1. Example of an ME30 solid model of a microcircuit package assembly Reduction in drafting effort A key factor in the acceptance of solid modeling at HP has been the reduction, or in some cases elimination, of traditional 2d orthographic documentation (shown in Figure 2). In many cases, HP engineers can have prototype parts and tooling made directly from the solid model. This is an important advantage for solids since drafting (adding dimensions, tolerances and notes) usually requires as much effort as initial design (defining a part's 2d or 3d shape). This also means that complete 2d documentation is only done once at the end of the project when the part design has matured and is ready for release to manufacturing. An example of a simple 2d cover sheet which would be sent to a manufacturer with the 3d model in lieu of a traditional blueprint is shown in Figure 3. This cover sheet conveys all the important information (critical tolerances, material type, finish, etc.) which is not included in the 3d geometry model. Once a 3d model of the part exists, generating the cover sheet drawing is a fast and easy process for the design engineer. Figure 2. Traditional 2d orthographic documentation for a machined part Completeness and ability to re-use design data Unlike 2d CAD drawings, 3d models are unambiguous and precise. For this reason, they can be easily re-used for downstream processes. HP engineers frequently re-use 3d models from other design teams or even other HP divisions in order to reduce development effort. Using solids, we create complete 3d models of entire products, eliminating the need for a physical prototype of a conceptual or initial design. Using electronic 3d data, distributed computing and networking allows distant development teams (in Colorado, Massachusetts and California for example) to communicate as if they were co-located. Our philosophy at HP is that design data should be created once and re-used as it moves from department to department, person to person, or tool to tool. We've found that 3d models created with an easily customizable CAD system like ME30, can be linked to many other tools and processes by using both standard (IGES, DXF) and custom applications or translators. Figure 3. HP's simplified documentation for the part shown in Figure 2. This drawing and the 3d CAD model it was generated from are used to manufacture parts directly from the ME30 solid model. Design Summary At HP we've found that proper use of solid modeling during design has yielded the following benefits: - Improved product design quality - Faster product development - Fewer physical prototypes during development - Improved team communication among the development team - More creativity and innovation ANALYSIS AND SIMULATION Solids modeling is a very simple form of simulation. Through its use, HP engineers can predict the ease of assembly or identify potential interference problems between parts in a complex assembly. We are usually interested in in more than just simulating geometry; our goal is to predict product performance with additional analysis and simulation tools. As with CAD, HP has tried to selectively limit the number of analysis tools down to a manageable few. This makes training, leverage and integration with CAD much easier. For now, HP's internal users have chosen to use: - Flotherm from Flomerics, which is a computational fluid dynamics package for predicting the flow and temperature of air through an electronics enclosure. Flotherm is not yet linked with CAD, but we are planning to establish this link in the near future. Seven HP divisions are currently using Flotherm. Figure 4 shows a sample of results from Flotherm. Figure 4. Flotherm results predicting airfow (velocity and direction) and air temperature in a 3d analysis model of an instrument - VSA from Applied Computer Solutions, which is a tolerance analysis tool for assemblies that can simulate the build-up of many assemblies, then identify the amount of variation that will occur and flag the main contributors to critical assembly tolerances. Data from ME30 is passed to VSA through the IGES interface. At this time, eight of HP's product divisions are using VSA. - Rasna's Applied Structure, which is a structural analysis and shape optimization program aimed at engineers rather than full-time analysts. ME30 surface data is currently passed to Applied Structure using IGES files. One division of HP is currently the primary test and benchmarking site for the company as a whole. These analysis tools are currently being used at a minority of HP divisions, but our goal is to improve their integration with CAD, and make these tools far easier to use, so that we can take greater advantage of simulation rather than building and testing physical prototypes during early design. In addition to these tools, HP has also developed some proprietary Design For Manufacturing (DFM) and cost analysis tools based on ME30 which are very useful for commonly used manufacturing processes within the company. These tools help guide engineers by identifying design features which are difficult or expensive to manufacture and by predicting the total manufacturing cost of a given 3d solid model. At HP, we've found it more difficult to implement analysis tools than 3d CAD, but the benefits from analysis tools can be important factors in reducing the development time of new products. In summary, here are some of those benefits: - More design iterations through the use of software models - Reduced need for expensive hardware prototypes - Better product design quality and reliability - Improved engineering confidence during development - Avoidance of warranty costs after product release PROTOTYPING Along with the reduction of drafting in design, effective use of prototyping has been a major component in HP's drive to improve its mechanical engineering process. HP's internal users have again chosen a small set of standard CAM tools which are very closely integrated with our 3d CAD environment. HP is currently using the following CAM software at more than 30 divisional manufacturing sites: - ME30 CAM, an internally-developed ME30-based program for doing fast and simple machining on manual milling machines which have been retrofitted with 2 axis Anilam controllers. - A customized version of Cimcam from Cimlinc for 2.5 axis NC machining. This is used for more complex machining jobs and includes both milling and turning capability for a wide variety of NC machines. - Merry Mechanization's SMP-81 for flat pattern layout, punching and forming of sheet metal parts. - ME30's stereolithography module for links to desk-top manufacturing. All of these software tools have been customized to link closely and easily with 3d models from ME30 without traditional 2d drawings. In fact, ME30 systems are used on the shop floor to receive the engineering data, visualize and understand the part to be made, and to select and convert portions of the 3d CAD data into the format required for the CAM process. This has lead to high technology HP shops where visitors can see machinists using their CAD systems to interactively rotate, slice or modify 3d models in order to prepare the designer's data for the NC process. Typical Prototyping Process A design packet (including a 3d model and simple 2d cover sheet drawing) is sent electronically by the designer to one or several internal manufacturing sites with the pick of a button from the ME30 screen. The designer is prompted for any other shop-specific information, and the data is sent to the shop through the HP-Internet transparently. E-mail messages confirming the delivery are sent to the shop, the engineer, and anyone else who needs to know (managers or production buyers). The incoming order and a picture of the part is automatically printed on a laser printer which signals the shop to begin making the part. A model maker reviews the design in the ME30 system and pulls out the data needed to make the part. If there are questions, the model maker and the engineer can share the same X11 window on each of their workstations while talking over the phone to discuss the design. The model maker then converts the design data to the needed manufacturing format and loads it into the CAM system to define the detailed processes which will be used to make the part. Using the engineer's 3d model to drive the manufacturing process has been a key factor in sharply cutting the cost and time required to manufacture high-quality parts. In summary, these are the benefits we've seen at HP: - Prototypes can be made in less than one half the time compared to our previous NC process which depended on 2d CAD drawings and manual programming. Even very complex designs, like the one shown in Figure 5, can now be transmitted through the network, translated into the CAM system for NC programming and manufactured in just a few days. Figure 5. This sheet metal part was designed in Waltham MA. and was manufacured in Santa Rosa CA. in 3 days - Improved part quality is attained, since the engineer's design data defines both the part geometry and the manufacturing process. There are no longer questions about missing dimensions or geometry from a 2d blueprint. Prototype parts are now expected to fit the first time without any re-work. - Time savings due to reuse of the 3d model to design tooling or fixturing required for manufacturing of the part. This is true for all types of parts including diecast or molded parts. Some new prototyping methods, like stereolithography, are only possible when a solid model of the desired part is available. - Better and more frequent communication between designer and manufacturer is now possible since they both have the same tools and relatively more time to discuss design for manufacturability. Most of the prototyping methods discussed so far also apply to external shops which HP uses for some prototyping and volume manufacturing. HP has teamed up with suppliers which are capable and motivated to work with 3d CAD data and limited 2d documentation. HP engineers can now send CAD data electronically to a variety of external suppliers through high speed modems or e-mail links using the same ME30 interface that is used for internal manufacturing sites. RELEASE TO MANUFACTURING Each HP division has a Manufacturing Specs organization which manages and archives engineering data after the product design is finished. At HP this group has the same CAD capability and equipment that is found in the R&D lab. As the CAD data is released from design to manufacturing, this organization updates and maintains both the 3d CAD models and the 2d drawings which are both archived for future use. In some cases traditional 2d documentation is created at the end of a development project if a long-term supplier requires traditional documentation. But in many cases the simplified 2d cover sheet is the only drawing that is archived and maintained with the 3d model through the entire life of the product. Having the same 3d CAD environment for both R&D and Manufacturing has improved communication and has helped to break down some of the differences that previously existed between the people in those organizations. An important tool and methodology HP has been employing during product release is called Product Data Management. PDM is a company-wide data base management tool which is a custom version of HP's commercially available WorkManager product. PDM is used to collect and manage all important electronic information that is created during product development. It is used as a central pool of data that can be accessed and shared by anyone within the company. Currently, PDM is primarily being used by the Manufacturing Specs community at more than 20 HP sites to collect, control, and distribute all types of engineering data at each HP site. However, in the near future, PDM will play an increasingly more important role in linking people at many distant HP sites who are all working on a distributed product development team. In the past, drafters or engineers spent a great deal of time creating complex isometric assembly drawings to illustrate how to put a product together, take it apart or how to service it in the field. With the adoption of solid modeling, creating this type of drawing from an existing 3d model of a product is very easy and is now frequently done to create illustrations for HP's technical documentation or a product's service manuals. All of these boil down to an improved release process which is now more continuous and error-free resulting in faster and less costly product delivery for HP. "HIDDEN" BENEFITS TO USING SOLIDS So far we've reviewed the positive impact of solid modeling has had on product development and the engineering process. Now we'll look at some of the effects that the technology has had on the people involved in using it. Creativity and Innovation Because engineers are now working with computer models rather than physical hardware, they are more likely to experiment and try new ideas. This has allowed HP's ME CAD users to work more creatively and apply new innovation to problem solving. Teamwork Improved teamwork has already been mentioned, but it should be highlighted as a significant advantage. Solids modeling offers a new way to communicate designs through realistic and often-times beautiful pictures of complex engineering models. These pictures, and the real-time animation that is possible with ME30, allow everyone to understand the design and are a good catalyst for getting people to discuss the product design. Morale HP's has been very successful in using MCAE technologies. Many HP people are very proud of the improvements we've been able to make in mechanical engineering environment over the last 5 years. This progress has fostered an unprecedented sense of confidence, morale and enthusiasm in HP's ME community. With this success has come more respect and even some admiration from HP's EE and software development communities about the effectiveness and productivity of HP's mechanical engineers. For many people it is simply fun and enjoyable to work in today's dynamic high-technology environment at HP. Visionary Thinking Even with all the changes that have occurred at HP, our people are still asking for further improvements. Why? Because they can envision an even better work environment in the near future. One which allows us to work more productively and creatively. Their expectation is to take full advantage of emerging technologies in order to make their work easier and more interesting as well as to develop even better new products at a lower cost, in a minimum amount of time. HP's VISION FOR BETTER MECHANICAL ENGINEERING Traditional product development is a serial process which is highly dependent on hardware (physical prototypes) and paper based information like drawings and material lists. Normally, each step must be completed before the next can begin. To communicate a design solution, it must be fully documented as a 2d drawing so that others can understand it in order to build or test a new part or assembly. Only after a product has been built can we see if the original design needs have been met. Traditionally, 3 to 4 costly and time-consuming prototypes were built and tested in order to develop a robust design. Figure 4. The traditional and HP's improved ME development process HP's new product development is a concurrent process which is highly dependent on the integration of software tools and the easy flow of electronic information between many people as it goes through this process. Today, we use computer design and simulation tools to predict the performance of a new design without spending money on many physical prototypes. This way, a design engineer can make many improvements and design iterations on the computer model without committing to these changes in an expensive hardware prototype. Periodically, a rapid prototyping cycle is used to verify the design and simulation models and to test the manufacturing process. Only when the design is complete is any traditional 2d documentation created. Drafting, which used to be the major activity in the old process, has been taken out of the critical path and has now become a one-time or optional last step in design before data is released to manufacturing. In the past, we had very specific tools for each serial step in the development process. Today we have a small number of computer tools which are used from start to finish by all people working on a development team. At HP these tools are ME30 for solid modeling, networking and the X11 window interface for providing communication and access to others, and data management tools like PDM to allow the sharing of the data that is generated during product development. In 1990 some of HP's leading engineers developed a 3-year vision of HP's mechanical engineering work environment. The vision was communicated, accepted and supported by engineers and managers throughout the company. This vision was meant to be achievable but also very challenging in order to stimulate everyone in the company to improve our ME tools and processes. Here is list of goals that define HP's vision for the next 3 to 5 years: 1991 Goals: - Design all new products using 3d solids - Attain prototyping capability from 3d models without traditional 2d drawings - Achieve commonplace use of stereolithography and desktop manufacturing - Begin the use of selected ME analysis and simulation tools - Release solid models to Manufacturing Specs 1992 Goals: - Tightly link ME and EE design systems and processes - Select and use standard tools for ME analysis and simulation - Achieve company-wide use of Product Data Management - Provide a corporate library of 3d models for design re-use - Improve integration between ME design and manufacturing information systems - Establish links between computer aided inspection and CAD/CAM 1993 Goals: - Provide all important engineering information on-line - Establish paperless processes and information flows - Link design, manufacturing and procurement systems into one work environment As a whole, HP has done very well in reaching our own goals for 1991. Here is a review of how we did at the end of 1991 (from a mini-survey of 26 HP divisions): - 75% of new design was created using 3d, a big increase from the previous year when only 35% of new design had been created using 3d solids. - More than 90% of HP divisions have manufactured parts without traditional 2d drawings. Almost all divisions send data to manufacturing electronically. - About half of HP divisions have tried the stereolithography process. - More than 70% of HP divisions are using some ME analysis tools. - Roughly 60% of HP divisions have released solid models to manufacturing. Obviously, there is a lot to be proud of in these achievements. However, 1992 is almost half over, and there is still a lot work to be done in the near future to reach the remaining vision goals. CONCLUSIONS By sponsoring and guiding comprehensive changes in its MCAE environment, HP has significantly improved its own product development processes. By taking advantage of solid modeling, improving CAD integration, and using networking, data management and ME simulation technologies, HP has been able to double its mechanical engineering productivity. These efforts have resulted in better quality products, faster product delivery and lower development costs. These results and a clear future vision demonstrate that HP is a world leader in the use of solid modeling for mechanical engineering.