VR visualisation technologies offer the opportunity to retrieve, review and assess data using several working scenarios in the design environment.  It was this capability that first attracted John Martin from BAE Systems Submarines to explore this field.

Their initial system from Virtalis consisted of a specialist graphical processor, a projector capable of stereo, an immersive headset with tracker and 3-D mouse and sound and video systems.

An early adopter of this technology, John commented: “VR offers the opportunity to retrieve, review and assess data using several working scenarios.  Since installation, the VR technologies have been extensively used on a daily basis by design and build teams on warship and submarine contracts including: LPD’s (Landing Platform Dock), Fleet Auxiliary Oil Tankers and Nuclear Submarines.  The system has also been used on ship concept design studies (aircraft carriers, surface warships and submarines) as a means of addressing key design issues, introducing simulation based design technologies and reviewing design solution options with the customer.  It has contributed to the introduction of concurrent design and to the synchronisation of an integrated design and build plan.“

“VR also offers the capability to add colour, texture, simulation animation, smooth flythrough, merging of models from several CAD sources and the optional of use of specialist peripherals, such as headset immersion.  We use VR as a visualisation tool to enable design and production and support customer teams to review a design layout, its detail and its underlying data attributes in a manner not available through conventional CAD systems.”

The LPD (Landing Platform Dock) surface warship was the first design build project to attempt a 100% digital definition and subsequently the first to use VR for formal design acceptance by the customer.  The LPD build strategy is based on seven large ‘block’ assemblies, which are fabricated and fitted to an advanced state in the build hall before being moved across site to the launch slip-ways for connection to adjacent blocks.  VR technologies were used extensively for formal and informal reviews of the evolving and completed design on a daily basis.

John explained: “We found VR helpful in production planning activities that were carried out during the design process to integrate the design and production requirements.  This helped us to achieve a cost-effective product that satisfied the design requirement.  All our design issues or identified production problems were resolved using visualisation of the model.  Simulation of equipment movement was used to prove removal routes, crew access for maintenance accessed, and verification of manufacturability, operability and feasibility were reviewed.  The team reached a general agreement in that the visualisation technologies significantly contributed to achieving an acceptable design and a realistic build outfit schedule.”

A second surface ship, the Auxiliary Oil Tanker, also used the processes and systems applied to the LPD and utilised the visualisation tools for regular internal and external design reviews.

The Astute Class of Submarine

BAE Systems Submarines’ Astute Class uses VR technologies both in its design and its manufacture.  In the past, submarine design has been supported by physical prototypes of either a full size wood mock-up or a scaled plastic model, both of which are expensive to produce in time and cost.  This means that the elimination of the physical prototype achieves considerable potential saving.

For the first time ever, advanced visualisation facilities, in the form of four VR enabled cabins and three VR suites are being used by the personnel working to build the boat instead of referring to a virtual prototype.  Although delivery is not scheduled to be complete until next year, with just the first cabin operational and in situ, the project has won the prestigious BAE SYSTEMS Submarines Chairman’s Bronze Award.

Lord Bach, the defence procurement minister, explained in 2003: “The Astute Class will be the most advanced and powerful attack submarines the Royal Navy has ever operated and these boats will play a key part of our defence for decades to come.”

The construction of the Astute Class is a tremendous technical challenge.  It bigger than any attack submarine previously built in the UK and there is no physical prototype.  However, the introduction of modular build techniques, coupled with the use of CAD and advanced visualisation is enabling these obstacles to be overcome.

John Martin, explained: “This was the vision for the use of Virtual Reality when it was decided not to rely on physical prototypes in 1997.  Being able to view the 3D virtual models in accessible cabins locally positioned on gantries surrounding the boat provides a direct replacement for expensive physical models.”

Keith Livingston, support manager for CAD/CAM application at BAE SYSTEMS Submarines, commented: “A very important aspect of these new VR facilities is that they provide real time access to the virtual model and related engineering data.  The images are mainly rear projected, which not only protects the equipment from a harsh environment, but it also allows our workforce to interact with the virtual models without casting a shadow.”

Ian Millard, applications engineer responsible for the implementation of the new advanced visualisation cabins and rooms at BAE SYSTEMS Submarines, said: “Our engineering data is now truly being shared by the manufacturing engineers responsible for building this boat.  These new facilities can be used in future to support the Astute through its service for refits and even for training purposes.”

Andrew Connell, technical director at Virtalis, said: “The relationship between BAE SYSTEMS Submarines and Virtalis goes back more than a decade.  BAE was an early adopter of this technology and is now reaping its rewards.”