# Presentation: 511239

## Enhancing Design-for-Manufacturability Using the ISO 10303 Standard for Electronics Design: AP210

- Presenter:
- Russell.Peak@marc.gatech.edu*http://itimes.marc.gatech.edu/*
*http://eislab.gatech.edu/projects/ *
- Russell.Peak@InterCAX.com*http://www.InterCAX.com/*

*2003 Aerospace Product Data Exchange (APDE) Workshop *
*April 7-9, 2003*
*NIST **• **Gaithersburg, Maryland *

## Authors and AbstractConference Series Archive: http://step.nasa.gov/

**Enhancing Design-for-Manufacturability ****Using the ISO 10303 Standard for Electronics Design: AP210**
**Georgia Tech (GIT):** Russell Peak (presenter), Manas Bajaj, Miyako Wilson, Injoong Kim
**Rockwell Collins (RCI):** Tom Thurman, Mike Benda, M. C. Jothishankar
**U. Illinois (UIUC):** Placid Ferreira, Jami Stori, Deepkishore Mukhopadhyay, Dong Tang
**LKSoft:** Giedrius Liutkus, Lothar Klein
- This presentation overviews recent work to deploy AP210 within Rockwell Collins to enhance the printed circuit assembly (PCA) design-for-manufacturability (DFM) process. PCA design models in the form of AP210 are created here by combining information from Zuken Visula electrical CAD models with other product model sources. The resulting AP210 models are then checked against corporate DFM guidelines implemented in a rule-based expert system.
- This work illustrates the challenges and benefits of addressing common engineering framework gaps, including gathering information from various sources, managing different levels of abstraction, and addressing semantic mismatches.

- X = design, mfg., sustainment, and other lifecycle phases.

## Primary GIT Technical Teamin Phase 1

- Mfg. Research Center (MARC)
- Russell Peak† - Project mgt., architecture, use cases, STEP
- Miyako Wilson† - Lead s/w developer, STEP, schema customization, RDD Model Creator (AP210-to-Kappa) development via java/jsdai
- Engineering Information Systems Lab (EIS Lab)
- Manas Bajaj‡ - Rules implementation (Kappa); RDD Model Creator dev. assistance; verification & validation testing
- Injoong Kim‡ - Oracle DBMS setup & interaction (CIM Library); RDD Model Creator dev. assistance; rules implementation; testing
- iTIMES Center - information technology for engineering
- †Full-time R&D staff		 ‡Graduate student

## Primary Technical Teamin Phase 1

- RCI *- end user context & support; AP210 support*
- GIT *- architecture; rules implementation; AP210 & DBMS interfaces*
- LKSoft/InterCAX *- Zuken CADIF-AP210 translator; STEP toolkit*
- CAM-I Simulation for Flexible Mfg. (SFM) project & PDES Inc. Electromechanical (EM) Pilot
- RCI *- project mgt. & teaming coordination*
- UIUC *- DFX analysis results visualization; pkg. modeler*
- Boeing *- rules framework support; AP210 support*
- ASU *- next-gen. knowledge-based systems survey*

- SFM = Simulation for Flexible Mfg.		RCI - Rockwell Collins Inc.      GIT - Georgia Tech     UIUC - U. Illinois     ASU - Arizona State University

## www.InterCAX.com

*LKSoft*
*U.S.-based representative  *
*for North America*
**Status: Open for business**
-  Received business licenses  etc. January, 2003
-  North American sales, project contracts, technical support, etc.
-  Close interactions with LKSoft European offices (e.g. for AP210 converter development & support)
-  Technology Director
-     Mike.Dickerson@InterCAX.com
-  Research Director
-     Russell.Peak@InterCAX.com
-  Managing Director
-     Dirk.Zwemer@InterCAX.com

## Other External Collaboratorsre: related technology ...

- PDES Inc. Teams
- Electromechanical (EM) Pilot
- Boeing, LKSoft, NASA, Rockwell Collins, US Army, ...
- Engineering Frameworks Interest Group (EFWIG)
- ~Above plus ATI, GM, NIST, ...
- Systems Engineering (SE)
- ~Above plus Eurostep (AP233 Demonstrator), LMCO, ...
- CAX Vendors
- Zuken, Mentor Graphics, Ansys, ...

## Contents 

- Context
- SFM DFX Checker overview
- AP210 context
- System walk-through
- System development architecture
- Verification & validation
- Challenges
- Summary & next steps

- SFM = Simulation for Flexible Mfg.	DFX = Design-for-Manufacturability, -Reliability, -Test, -Maintenance, ...

## STEP AP210 (ISO 10303-210) Domain: Electronics Design

- STEP AP210 (ISO 10303-210) *Domain: Electronics Design*

*~950 standardized concepts (many applicable to other domains)*
*Development investment: O(100 man-years) over ~10 years*

- 2003-04 - Adapted from 2002-04 version by Tom Thurman, Rockwell-Collins

- Configuration Controlled Design of Electronic Assemblies,their Interconnection and Packaging

## STEP AP210  Models

*STEP AP210  Models*

**Assembly Models**

-   User View
-   Design View
-   Component Placement
-   Material product
-   Complex Assemblies with Multiple Interconnect

**Component / Part Models**

-   Analysis Support
-   Package
-   Material Product
-   Properties
-   “White Box”/ “Black Box”
-   Pin Mapping

**Requirements Models**

-   Design
-   Constraints
-   Interface
-   Allocation

**Functional Models**

-   Functional Unit
-   Interface Declaration
-   Network Listing
-   Simulation Models
-   Signals

**Interconnect Models**

-   User View
-   Design View
-   Bare Board Design
-   Layout templates
-   Layers
- planar
- non-planar
-         conductive
-         non-conductive

**Configuration Mgmt**

-   Identification
-   Authority
-   Effectivity
-   Control
-   Net Change

**GD & T Model**

-   Datum Reference Frame
-   Tolerances

## Rich Features in AP210: PCB Assembly - 3D & 2D STEP-Book AP210 Browser - www.lksoft.com

- PDES Inc. EM Pilot
- Test Case:
- Cable Order Wire
- (COW) Board

## Rich Features in AP210: PWB tracesAP210 STEP-Book Viewer - www.lksoft.com

## Rich Features in AP210: Via/Plated Through Hole 

- Z-dimension details ...

## Rich Features in AP210: Electrical Component

- The 3D shape is generated from these “smart features” which have electrical functional knowledge.  Thus, the AP210-based model is much richer than a typical 3D MCAD package model.
- 210 can also support the detailed design of a package itself (its insides, including electrical functions and physical behaviors).

## Envisioned Standards-based “Data Bus”

**Iterate**

**Iterate**

**Manufacturing**

**Circuit Board**
**   ****Assembly**

**Iterate**

**Iterate**

**Manufacturing**

**Electrical**

**Mechanical**

***Quality***
***Product***

**STEP Data **
**for Exchange**

**Multi-Card**
**Module**

**System Engineering**

- AP 233

**AP 210**

- PWI 220

- 2002-03 - Tom Thurman, Rockwell-Collins

## Contents 

- Context
- SFM DFX Checker overview
- AP210 context
- System walk-through
- System development architecture
- Verification & validation
- Challenges
- Summary & next steps

- SFM = Simulation for Flexible Mfg.	DFX = Design-for-Manufacturability, -Reliability, -Test, -Maintenance, ...

## AP210-Based DFX Analysis Process Rockwell Collins (RCI) SFM Project

- Model
- Information

- CAD/E/M/X Tools

- DFX
- Guidelines

- Automated
- DFX Checking

- DFX
- Analysis Results

- DFX = Design-for-Manufacturability, -Reliability, -Test, -Maintenance, ...	SFM = Simulation for Flexible Mfg.

*STEP AP210*

- Other Design Verification
- Analysis & Simulation

*SFM Project Focus:*
- High-value rules
- not supported
- by typical CAD tools

## Example DFM Rule and Implementation

- Boeing Rules Definition Facility (RDF):
- Rule Meta-Data (computer-sensible)

- DFM Document(human-sensible)

## AP210-Based DFX Analysis Process Rockwell Collins (RCI) SFM Project

- Model
- Information

- CAD/E/M/X Tools

- DFX
- Guidelines

- Automated
- DFX Checking

- DFX
- Analysis Results

- DFX = Design-for-Manufacturability, -Reliability, -Test, -Maintenance, ...	SFM = Simulation for Flexible Mfg.

*STEP AP210*

- Other Design Verification
- Analysis & Simulation

## RCI Design -502 in STEP Book AP210

- Production design: -502
- 728 components; 6 layer stackup

**Notes:**
Note: this is from the STEP-Book version included with the a6 release of the LKSoft CADIF-210 translator.  The design model is from the translator plus manual edits by RCI to include additional information.

## AP210-Based DFX Analysis Process Rockwell Collins (RCI) SFM Project

- Model
- Information

- CAD/E/M/X Tools

- DFX
- Guidelines

- Automated
- DFX Checking

- DFX
- Analysis Results

- DFX = Design-for-Manufacturability, -Reliability, -Test, -Maintenance, ...	SFM = Simulation for Flexible Mfg.

*STEP AP210*

- Other Design Verification
- Analysis & Simulation

## AP210 Design Input & Rule Checker Execution

- AP210 Design Input
- (in LKSoft STEP-Book via CADIF Converter)

- Rule Checker Execution
- (in Boeing REF Tool)

## AP210-Based DFX Analysis Process Rockwell Collins (RCI) SFM Project

- Model
- Information

- CAD/E/M/X Tools

- DFX
- Guidelines

- Automated
- DFX Checking

- DFX
- Analysis Results

- DFX = Design-for-Manufacturability, -Reliability, -Test, -Maintenance, ...	SFM = Simulation for Flexible Mfg.

*STEP AP210*

- Other Design Verification
- Analysis & Simulation

## UIUC DFX Results Viewer RCI Design Rule Violation Example

- Results Log
- (from SFM DFX Checker)

- Results Browser
- (highlighted features
- have DFX violations)

## AP210-based SFM DFX Checker(see PDES Inc. Electromechanical Pilot slides)

- AP210-based *SFM DFX Checker*(see PDES Inc. Electromechanical Pilot slides)

- Model
- Information

- CAD/E/M/X Tools

- DFX
- Guidelines

- Automated
- DFX Checking

- DFX
- Analysis Results

- DFX = Design-for-Manufacturability, -Reliability, -Test, -Maintenance, ...
- SFM = Simulation for Flexible Mfg.

*STEP AP210*

*Status at Rockwell Collins - Rules Set 1*
-    Jan ’03 	- Pre-production testing
-    Mar ‘03	- Pilot production testing
-    Spring ’03	- Full production release

## Contents 

- Context
- SFM DFX Checker overview
- AP210 context
- System walk-through
- System development architecture
- Verification & validation
- Challenges
- Summary & next steps

- SFM = Simulation for Flexible Mfg.	DFX = Design-for-Manufacturability, -Reliability, -Test, -Maintenance, ...

## SFM DFX Checker (SDC) ArchitectureEnd User Views: DFX Librarians & Design Analysts          SDC v1.0.b03+

- Version: 2003-03-25

- RCI - Rockwell Collins Inc.      GIT - Georgia Tech      UIUC - U. Illinois

## SFM DFX Checker (SDC) ArchitectureSystem Composition View: Development & Deployment          SDC v1.0.b03+

- SFM DFX Checker (SDC) ArchitectureSystem Composition View: Development & Deployment          SDC v1.0.b03+

- Visula

- Design
- Information

- ECAD Tool

- RCI DFX
- Guidelines

- DFX
- Analysis Results

*CADIF*

- DTI
- Informix DBMS

- PWA/B
- Properties

- Design Aux File

*dti (text)*

- CADIF-AP210
- Converter

- Model
- Transformer

*REF_log.txt*

- Boeing
- RDF

- Authoring Tool

- RCI DFX
- Rules Library

- RDD Model
- Creator
- (SDC-RMC)

- Model
- Transformer

- Stds.-based
- Design Model

*STEP AP210*

- Augmented
- Design/Mfg. Model

*RDD model (.kal)*

- Feedback for Design
- Readiness / Changes

- Version: 2003-03-25

- RCI - Rockwell Collins Inc.      GIT - Georgia Tech      UIUC - U. Illinois

- Zuken

- LKSoft

- GIT

- Rules Execution
- Facility (REF)

- Analysis Tool

- Boeing

- GIT

- Rules Definition
- Facility (RDF)

- Boeing

- Results Mgr.
- (SDC-RM)

- Reviewer Tool

- UIUC

- Other CAD/E/X
- Tools

- GIT

- Boeing Rules System (BRS = Kappa + RDF + REF)

- SDC Rules Tool (SDC-RT)

- SFM DFX Checker (SDC)

- RDD = intermediate design & mfg info model
- (custom application-oriented model)

- Component Library Files *(.csv)*
- Auto & Manual Generation

- Component
- Mfg.-related Info.

## Engineering Standards-Based Client-Server Architecture - LKSoft

**Mapping **
**(ARM-AIM)**

**Classic**
**STEP File**
**STEP-p21**

**STEP - p27**

**Meta****-D****at****a**

**Multiple**
**Schemas**
**& Models**

**Local Repositories**

**Remote Repositories**

**AP210 Interfaces (ECAD):**
** ****EAGLE / CadSoft**
** ****CircuitCAM / LPKF**
** ****VHDL**
** ****BoardStation / Mentor**
** ****Visula / Zuken**
**STEP-Book AP210**

**AP214 Interfaces (MCAD):**
** ****EDAG / eMatrix (PDM)**
** ****DXF**
** ****MicroStation-J**
** ****eM-Planner / Tecnomatix**
**STEP-Book AP214**

**STEP-Book Toolkit**
**  ****GUI widgets****   (lists, 2d/3d viewers, ...)**
**  ****Wizards**

**Web-based**

**Workstations**

**SdaiEdit **

**AimToArmAnalysis**

**Model**** Exchange**

**Applications**

**STEP-Book AP203 (MCAD)**

**Custom STEP-Book-based****Applications**

**Oracle**

- Using commercial LKSoft tools (www.lksoft.com)

*pXX / APyyy = ISO 10303 part XX / APyyy (in STEP standard series)*

- Source: LKSoft with GIT updates 2002-10

## Contents 

- Context
- SFM DFX Checker overview
- AP210 context
- System walk-through
- System development architecture
- Verification & validation
- Challenges
- Summary & next steps

- SFM = Simulation for Flexible Mfg.	DFX = Design-for-Manufacturability, -Reliability, -Test, -Maintenance, ...

## Verification & Validation

- RCI designs & cases (for primary V&V)
- ~10 production designs
- ~8 V&V test case designs
- Exercise specific DFM rules for V&V
- Unit test cases (manually created kappa models to aid rules development process)
- Type A: for full intended passing *(ensure no false negatives)*
- Type B: for selectively induced violations*(ensure no false positives when have all needed data)*
- Type C: for checking if design model has insufficient data*(ensure no false positives when have insufficient data)*

## RCI V&V Case -051 in STEP Book AP210

- RCI V&V Case -051 in STEP Book AP210

## RCI Test Cases -053 and -503 in STEP Book AP210

- V&V design: -053
- fiducials test;16 layer stackup

- Production design: -503
- 1043 components; 20 layer stackup

## Contents 

- Context
- SFM DFX Checker overview
- Verification & validation status
- Challenges
- Summary & next steps

- SFM = Simulation for Flexible Mfg.	DFX = Design-for-Manufacturability, -Reliability, -Test, -Maintenance, ...

## Information Capture Gaps:Content Coverage and Semantics

- Information Capture Gaps:Content Coverage and Semantics

**Existing Tools**

*Tool A**1*

*Tool A**n*

*...*

**“****dumb” ****information capture**
- (only human-sensible,
- I.e., not computer-sensible)

_**Legend**_

**Content**
**Coverage Gaps**

**Content**
**Semantic Gaps**

**Smart Product Model**
*Building Blocks*** **
-  Models & meta-models
-  International standards
-  Industry specs
-  Corporate standards
-  Local customizations
-  Modeling technologies:
-  Express, UML, XML, COBs, ...

- Example “dumb” figures

## Contents 

- Context
- SFM DFX Checker overview
- Verification & validation
- Challenges
- Summary & next steps

- SFM = Simulation for Flexible Mfg.	DFX = Design-for-Manufacturability, -Reliability, -Test, -Maintenance, ...

## SummaryPhase 1 Accomplishments

- Established methodology and team approach
- Refined system architecture
- Component library approach
- Addressed challenges
- Information gaps
- Multiple updates to requirements, tools, standards
- Implemented higher value rules (plus other rules)
- Validation & verification ~complete
- Higher priority rules ready for RCI pilot production usage
- On-track for full production usage (~Spring 2003)