The construction of the Astute Class of submarine is a tremendous technical challenge. Three have been ordered by the Royal Navy, with the first due for launch in the summer of 2007. Not only is it more complex than any attack submarine previously built in the UK, but there is also no physical prototype available to guide those involved with the construction, and the project has seen the successful introduction of modular build techniques.
Contractor, BAE Systems Submarines had the rather novel idea of using stereo virtual reality (VR) on the shop floor to help the technicians and fitters involved in their day-to-day work constructing these complex machines. The company was assisted in this project by advanced visualisation specialist, Virtalis.
All those working on the vessels are able to view 3D virtual models in accessible cabins, locally sited on gantries surrounding the construction area. Both Astute, whose hull is complete and is now fitted out, and Ambush, which is at the vertical outfitting stage, each have a dedicated VR cabin, and each is capable of running the other’s models should one cabin be booked or unavailable. Chris Foote is a full-time pipe fitter who also regularly operates one of the cabin systems. He is one member of a team of people who keep this resource open as required. He takes up the story:
“People just drop in and look at the compartment they are working on. Sometimes they stay ten minutes, sometimes they stay an hour. If there is a particular problem they are wrestling with, they might pre-book a cabin. I drive the system for them, but because I have manufacturing and boat-building experience rather than an IT background, I can bring my practical experience to bear.” Mr Foote’s colleague, Dean Brown oversees quality control and is enthusiastic about this installation:
“I’ve worked with physical models and they weren’t always available when there had been design changes. Also, the physical models were just perspex and colour-coded plastic. The VR models give you a very real sense of the boat from the inside. People can literally stop by and walk through the exact area they are building.” Keith Livingston, support manager for CAD/CAM applications at BAE Systems Submarines adds:
“A very important aspect of these new VR facilities is that they provide real time access to the virtual model and related data. The images are mainly rear projected, which not only protects the equipment from the harsh environment, but also allows our workforce to interact with the virtual models without interfering with the projected image. Virtalis has also carried out work optimising the data production process for the models we create. This improves the performance of the VR cabins and shaves off valuable minutes of load time for the desktop 3D available to all the Astute engineers.”
Virtalis supplied BAE with two VR enabled cabins and three VR suites, each consisting of Christie projectors driven by server PCs. When the project was at an early stage and only part completed, it won the BAE Systems Submarines Chairman’s Bronze Award for 2005.