Manufacturing Technology developments at Wärtsilä Ship

Manufacturing Technology developments at Wärtsilä Ship

Manufacturing Technology developments at Wärtsilä
• Company & organization
• Product groups
• Design aspects
• Fixed Pitch Propeller production (movie)
• Manufacturing Technology:
CAD, CAM, PLM
Blade production line, CNC, robotics
Hub part machining
• Technology Development projects:
Design
Manufacturing
• Conclusions and implications for the future
Manufacturing Technology Developments in Wärtsilä Propulsion
Fontys
30 november 2006
by: André Janssen
Manager Manufacturing Technology & Tools
© Wärtsilä
© Wärtsilä
History
Ship Propellers
Lips Since 1882
www. wartsila.com
Our experience in Controllable
Pitch Propellers dates back to
1903 when the Wichman
company from Norway made
its first designs.
radar boat
© Wärtsilä
+/- 370
Bennet Woodcroft 1832
Bernoulli’s prop. 1770
Griffit
1849
Bramah’s prop.
Ericsson’s
1836
1785
Edward Shorter 1803
Hirsch
1860
Joseph Ressel
Taylor
1907
1829
•
1925
1934
1987
1998
2001
2002
© Wärtsilä
Dufay steel foundry at s’Hertogenbosch
Lips steel foundry at s’Hertogenbosch
Lips bronze foundry at Drunen (Max Lips president)
Lips (Investment organization)
TI-group
John Crane-Lips
Smiths-group
John Crane-Lips
Wärtsilä-group
Wärtsilä-Propulsion-NL
Wärtsilä operates in two markets
Wärtsilä Organization
Wärtsilä
IMATRA (Steel)
Ship Power
Power Plants
Service
Engine division
2 Stroke
4 Stroke
Propulsion
Solutions
Seals & Bearing
Propulsor
Business
W-Lips Defence
W-Lips Inc.
USA/Pacific
„ Ship Power and Service – growth through increased product
range and aquisitions
„ Power Plants – focus on the growing decentralized power
generation market
Sales
CPP
FPP
ST-TT-WJ
Controls
S&AS
Central
services
General
services
„ Technological leadership
© Wärtsilä
© Wärtsilä
Ship Power
Ship Power: 28%
Power Businesses
net sales
2005: 2,500.0
Propulsor: 25%
Ship Power businesses
Design
Engineering
Manufacturing
Project
management
DID YOU KNOW THIS?
Every third ship sailing the seas today has Wärtsilä
equipment installed. This demonstrates our capability,
commitment and the trust we enjoy among
shipbuilders and ship owners around the world.
Commissioning
Lifetime
support
2-stroke
Wärtsilä
2004©
presentation
© Wärtsilä
4-stroke
Propulsion
Solutions
Wärtsilä Propulsor products
Controls
Engines
Gears
Segment
structure
Wärtsilä Propulsion
Seals
Bearings
Brands
Segments
FPP
Thruster/Jets
Transverse Steerable
thruster
thruster
E-Pod thruster
Waterjets
CIPS
FPP
CPP
CPP
© Wärtsilä
© Wärtsilä
Wärtsilä Propulsor
Wärtsilä on map
4-stroke, Delivery Centre Vaasa, Finland
Auxpac
Wärtsilä 20
Wärtsilä 32
Wätsilä Vasa 32LN
Wärtsilä 32DF
Propulsion, Rubbestadneset, Norway
Drunen, the Netherlands
Biopower power plants, Kiuruvesi, Finland,
BioEnergy thermal plants
Oil and Gas boilers
CPP, Controls, Rudders and Reduction Gears
Propulsion, Drunen, The Netherlands
CPP, FPP, CIPS, Steerable Thrusters and Waterjets
Propulsion, Heerleen, The Netherlands
Transverse Thrusters
Propulsion, Havant, UK
Strerntube Seals Face Type
Strertube Bearings
Lineshaft Bearings
2-stroke,
Winterhur Swittzerland
4-stroke, delivery
Centre Trieste, Italy
Wärtsilä 26
Wärtsilä 38
Wärtsilä 46
Wärtsilä 46F
Wärtsilä 50DF
Wärtsilä 64
Wärtsilä ZA40S
Head Quarters, Helsinki Finland
Propulsion, Toyama, Japan
Strentube Seals Lip Type
Strerntube Bearings
Lineshaft Bearings
2-stroke, Poland
H. Cegielski-poznan
2-stroke, Croatia
3. Maj
2-stroke, Korea
Hyundai
Doosan Engine
2-stroke, china
Dalian
2-stroke, China
Yichang
2-stroke, Shanghai, China
Auxpac
Wärtsilä 20
2-stroke, Japan
Diesel United
Mitsubishi
NKK
2-stroke, Taiwan China steel
Machinery Corp.
Production
Joint Venture Production
R&D
Licencee
Sales
Service
Representatives
© Wärtsilä
Wärtsilä Propulsion Netherlands B.V.
g
Operational Center Of Excellence for:
- CPP
- FPP & CIPS
- Steerable Thrusters & Waterjets
g
Machine shop and foundry
g
System Integration
g
± 600 employees
2-stroke, Japan
Hitachi Zosen
Propulsion, Wuxi, China
Transverse Thrusters
2-stroke, China Hudong
Propulsion, Zhenjiang, China
FPP
Propulsion, Khopoli, India
Reduction Gears
g
© Wärtsilä
Market drivers
Market drivers
Operational cost
„ Cost of equipment to be competitive
„ At the same time guarantees on innovations have to be given
„
„
„
„
„
„
„
Environmental performance
FPP
z Current market requires:
and products must be reliable
Dedicated solutions
Short lead times
Excellent fuel performance, low emissions
Good steering performance (ST)
More accurate power response (CPP)
Quiet propulsion systems
Fleet and equipment monitoring
Weather routing, fuel optimisation and efficiency
Noise, vibration and
exhaust emission
control
Efficiency
rudder
Low speed operations
Operational performance
Nozzles
Dynamic Positioning, thrust and reliability
Auto-Docking &
voyage optimisation
Pitch governing
Short berthing time
© Wärtsilä
© Wärtsilä
Lips® Fixed Pitch Propellers
With fixed pitch propellers the design will be optimised for one operational
condition; achieving superior propeller efficiency.
; State of the art propeller design resulting in high propeller efficiencies
and low pressure pulses
; More than a century of experience in
propeller design and manufacturing
STT
CPP
WJ
Productgroup Fixed Pitch Propellers (FPP’s & CIPS)
z Casted in one piece
z Application ships moving straight
forward
z Dimensions from 0.4 till 12 meter
diameter
z Netto weight 11 kg till 94.600 kg
(casted max.120000 Kg)
z Power from 500 kW till 80.000 kW
; Use of patented material with
proven outstanding mechanical
and fatigue properties in seawater
; One-stop-shop for total
propulsion packages
© Wärtsilä
26 - Wärtsilä
Marine
TT
© Wärtsilä
Lips® Controllable Pitch Propellers
World-class performance with regard to propeller
efficiency, low noise, vibration levels and reliability.
Wake adapted high performance propeller designs
Complete installations incl. shafting, hydraulics,
Productgroup Controllable Pitch Propellers (CPP’s)
z Propeller with adjustable blades to reach the maximum
power during each condition
z Application area ships who must be manoeuvrable
z Dimensions till 9,8 m ( hubdiameter 2,8 m)
z Largest power on an adjustable propeller is 44 MW
controls and accessories
Robust mechanical designs
z System consists shaft, hydraulic and electronic control
Reliable and safe
Propeller blades of stainless steel or NiAl bronze
© Wärtsilä
25 - Wärtsilä
Marine
© Wärtsilä
Lips® Steerable Thrusters
Blue Marlin and Thialf
Wärtsilä delivers steerable thrusters for offshore,
sea going and tug applications in modular, retractable
and underwater mountable designs
z Blue Marlin; heavy load vessel
z Owner: Dockwise
z Wartsila supply:
„ 2* ST type CS3500, each
4500kW
; Tailored hydrodynamic designs based on wide
experience with propulsion systems
; Unique procedures and solutions available for
mounting the thrusters underwater even in
sea states
z Thialf; Deepwater construction vessel
z Owner: Heerema Contractors
z Wärtsilä supply:
„ 2x ST, each 5500 kW
; 360º rotating for optimal manoeuvrability
; High efficiency nozzles for improved performance
; Available up to 7 MW
© Wärtsilä
28 - Wärtsilä
Marine
© Wärtsilä
Lips® Jets
„ Market position
„ Major supplier in the world
Typical examples of ships :Hybrid propulsion system
z Trials 86m Yacht van Lent
„ Contractual speed of 30 knots easily achieved (34 knots at full GT
„ Market segments
„ Fast ferry
„ Navy
„ Yachts
power)
„ Unique Selling Points
„ State of the Art design
„ Long life time
„ Low maintenance costs
„ Lightweight construction
„ Speeds up to 70 knots (130 Km/h)
Waterjet
Props
kW)
© Wärtsilä
© Wärtsilä
Wärtsilä® Gears
The Wärtsilä gears have been designed to meet the highest standards of
operational efficiency, reliability, low noise and vibration.
Lips® Transverse Thrusters
Wärtsilä delivers transverse thrusters for all different
kind of vessel types.
Single input, single output
with
vertical and horizontal offset
Twin input, single output with
up to 3.8 m offset
Integrated or separate
hydraulic system for gear and
CP propeller
© Wärtsilä
24 - Wärtsilä
Marine
: 1xLJ210E (23.000 kW)
: 2xHigh Skew CP (2x4.640
; Controllable or Fixed Pitch Propeller
; Robust and reliable design
; Easy installation
; Low noise versions
© Wärtsilä
28 - Wärtsilä
Marine
S&AS Controllable Pitch Propellers
Hydrodynamics
State-of-the-art Design
z Tailor-made designs
„ Wake-adapted, high
efficiency
„ Low noise and vibration level
„ No cavitation erosion
„ Full scale references
z Design based on mission profile
„ Reduction of fuel
consumption
z Match of propeller with engine
„ Increased reliability and
lifetime
z CFD (Computational Fluid
Dynamics) calculations
„ Design for full scale
z Co-operation with marine model
test institutes
„ Independent and scientific
support
z Wärtsilä service concept and the
world wide network of more than
5000 professionals
in over 50 countries ensure the
best possible lifetime support.
z International network of service
and repair licensees
z Service portfolio comprises:
- training
- technical support
- field service
- workshop and repair
- upgrading and modernisation
© Wärtsilä
© Wärtsilä
Ship power development
Production Fixed Pitch Propellers
Historical development of maximum power
applied per ship propulsor
Power [kW]
70000
60000
50000
Fixed Pitch Propellers
40000
30000
Controllable
Pitch Propellers
Jets
20000
Podded
Propulsors
10000
0
1800
© Wärtsilä
1820
1840
1860
1880
1900
1920
Year
1940
1960
1980
2000
2020
© Wärtsilä
WP - key customer/support processes/people
Change management
Today’s technical software challenges
&
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Bu
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Vision on product structures & technical software
NS
Hydrodynamic
Design
OW
KN
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DG
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Mechanical
Engineering
Manufacturing
Sales
Purchase Service
Processes
Integrated Product Data Structure
Knowledge, file and application manager
TIO
LU
Global-PDM
U
OD
PR
“Standard” Third party
Special
Applications: Applications: Applications;
ACAD
UGS-PLM
MS-office
……….
Product Information/Management Systems
PUF
ANSYS
VIEWCAST
……….
MODELS
MATERIALS
CONFIGURATIONS
WVINP-WVB
KNOWLEDGE
DUCTPROP
PROJECTS
SPRESS
REPORTS
TECHNICAL
DATABASE
DRAWING
&
DOCUMENT
ARCHIVE
SAP MSQ
………..
Business Tools
… MSQ … BOM … EDM … INCLASS .. dig. ARCHIVE.. CAD ….. CAM … PDM … SAP
Projects/time/transformation
© Wärtsilä
Wärtsilä Propulsor Business
© Wärtsilä
Vision on standard & special software multi site
Vision on NX-3D CAD master models and associativities
Product Data Infra Structure
Requirements
Requirements
Hydr. design
Mech. engineering
Workpreparation
Production
Design (hydr.+ mech.)
Applications/DATA
Fortran
applications
Buy
Design-Engineering-
Knowledge
Standard applications
Make
Manufacturing
Third party applications
Foundries &
Special applications:
Machine shops
.... ...hyd-mech-mfg
Collaborative desktop-design & manufacturing
Product Information/Management/Knowledge System
Appl.
Tech.dB
TC
TC ?
TC
TC
TC
TC
TC
Team Center (metadata)
Oracle (volume data)
© Wärtsilä
TC
TC
TC2SAP
CFD
propeller
Automation
- Ufunc
FEM
3D NX4TC2005
CAD-nominal
CAD-Blank
CAD - Midtol
CAD-Manufacturing
CAD-Analyse
CAD-shrinkage
CAM-data
hydrodynamic
description
2D
Quaestor
- Ufunc
CAD-Mastermodel-Associative-KDA-CAM
Database
Resources
Models
Configurations
NC-Code
Shopdocs
- operations
- setup sheet
- toollist
- nc-listing
RS 6000
AS 400
Resources
ERP
IS&V
In process Simulation and Verification
parameters
PC LAN
methods
UG-Manager
- Templates
- NX1 = V8.1
- V15 = V5.0
BN
KS
VR
RA
BF
CC
PM
BC
FN
CN
KC
printers
plotters MK
DW
extern HG
KG
KX
DNC
Fasys
I-man
web
I-man
… MSQ … BOM … EDM … INCLASS . dig.ARCH... CAD … CAM … PDM … SAP
TC2MSQ
Customer needs
Development &
mechanical
part
description
dBase
Analyse
MSQ
TC
?
Knowledge based Engin.
Windows-XP
What
© Wärtsilä
- Tools
- Fixtures
- Machines
- Controllers
- Feeds
- Speeds
- Cim source
- Operations
- Programs
- Methods
- Wizards
- Proc. Assist.
- shrinkage
Knowledge Fusion
HOW
Automation
- GRIP
- UFUNC
- TCL
FTN
Robots
Management Production
When-Where
Data
TeamCenter data associativity & management
derived part/new part: links, copy, simlify, allowances, casting,block
•Reverse Eng. part
•Import eng. part
3D blank part
3D Blank part
Assembly
NX, TC and SAP systems for WP-multi site
NX (CADCAM)
shopdocs:
SOLID
TC (PDM)
SAP (ERP)
CAD
Standard /
templates
CAE
As-engineered
MM/PP Module
operation plan
set-up’s
dataset:
associativity
• pdf
• workflow
Process Planning
part-info
TC-ITEM
eng.
libs.
Data Management (meta)
Design & Engineering
3D eng. part
general doc
blank or ipw
mfg. part-2
mfg. part-X
set-up-2
Shopdoc
IS&V
IPW
NC
2D Drawing
engineering
As-built
toolpaths/NC
set-up-1
part
As machined-2
CAM
fixture/tools
As machined-1
!
hod
met
Old
Change
requests
tool list
3D mfg. part-1
• prt---------Æ
Shopdoc
Engineering NB
Other (250)
WPNLapplications
mfg.
libs.
CS Module
Engineering S&AS
As-maintained
As-delivered
IS&V
As machined-x
NC
Shopdoc
set-up-X
IS&V
“no facetted model “
as-mfg.
part
NC
set-up-as machined
Shopdoc
Fortran
IS&V
© Wärtsilä
ENGINEERING
MANUFACTURING
WPNL example parts, processes and tools
Wärtsilä propulsion multi site clusters
WP Drunen NL
TC
ODS= Object
Distr. Server
WP Norway
TC
Oracle (volume)
Access
© Wärtsilä
Solid parts/processes:
WP Wuxi China
De
v
pro elop
duc
t
TC
Workprep.Mfg. Progs. since 1960
•
Manual CNC-programming since 1970
•
2DCAD 1983, 3DCADCAM 1988
•
CADCAM-NX2 2004
LAN
2 mbps
2 mbps
WP Publication
Server
2 mbps
……
WAN-infonet
……
….
.
Ma
nuf
a
ass cture
em
a
ble nd
Work in Progress
WP Web
Free form parts/processes:
Released Data
WEB clients
WP Web Clients
© Wärtsilä
•
Viewing
Info
•
Workprep.Mfg. Progs. since 1960
•
3DCADCAM 1988
•
Workprep.Mfg. Progs. CADCAM 1988
•
CADCAM-NX2 2004
© Wärtsilä
Example core parts Controllable Pitch Propeller
Free form parts & milling/finishing machines at Wärtsilä Drunen
SOLID FREE FORM PARTS:
Blade surfaces
Edges
Fillet/blending
Bladefoot
SOLID PARTS:
Hub cover
Blade carrier
Shaft
Sliding block
Moving cylinder yoke
© Wärtsilä
Hub body
Solid parts & milling-drilling- & turning machines at Wärtsilä
Drunen
• Milling & grinding robots
• 5-axis simultaneous milling machine
• Mobile measurement system, dedicated measuring machines
© Wärtsilä
TO-BE production chain example for blades (blade line)
Customer needs
design geometry
milling-grinding
NC-simulation
paths
robot-simulation
solidification
-simulation
Customer product
mouldgeometry
as-built information
Design/Engineering/MFG.
Integrated Product Data Structure
Knowledge,
Knowledge, file
file and
and application
application manager
manager
photogrammetry
manual grinding
• Horizontal- & vertical(carrousel) lathe machines
• Machining centers, Milling machines, Drilling machines,
• Laser
© Wärtsilä cutting
© Wärtsilä
robot milling
mould assy and
pouring
robot finish
5 axis simultaneous milling
2D machining
CPP-blade design & work preparation
CAD blade model
Robot grinding of EPS patterns
CAD blade appl. program
CAD pattern model
© Wärtsilä
© Wärtsilä
Blade line production : foundry
Blade line production: key mfg. processes
EPS patterns
Sand moulds
Bronze
Blade
measuring
BM-Mora
Blade
grinding
BLmanual
Robot
grinding
RA-ABB
5 axes
machining
center BF-Kolb
Boltline
© Wärtsilä
© Wärtsilä
Blade foot
machining
center KBSkoda
Portable
Measurement
PM-Solo
3D CAD CAM, Product & Production set-up
Schematic overview CAD, CAM, PDM
PDM (database Teamcenter)
CAD
CAM
Tool paths
. DEF
. TCL
. VNC
postprocessor
interactive automated
template
template
stand.func.
User Cycle
.doc
.NC
PC
PC
.VNC
postbuilder
WH105-iTNC
ASSY
shop data & docs
© Wärtsilä
© Wärtsilä
3D CADCAM for tooling design
NC program and shopdoc generation
B
D
A
C
E
Automatic generation of: A=part info, B=tool list, C=set-up sheets, D=simulation, E=NC data file
© Wärtsilä
© Wärtsilä
Simulation NC machining prismatic & free form parts
Design technology development projects
Project: Contra rotating propeller efficiency 10-17%
Project: Health monitoring
To / from ships’ network (fieldbus)
Pitch
Azimuth
Advanced CBM data
RPM
Data fusion (fuzzy based)
Envelope
Vibration
spectra
Oil
state
Decentralised
System
Accelerations
Project: 3S Energy
Project: Material improvement
Oil temp. (viscosity), additives, water, particles
Project: Propeller efficiency measurement
Project: Rudder efficiency 5-10%
© Wärtsilä
© Wärtsilä
Manufacturing technology development projects (1)
Project: milling versus grinding
Project: shrinkage knowledge
Project: CAM-TC structures/data
Manufacturing technology development projects (2)
Project: Hub component line (total machining)
Project: Meten=Weten
Blade line
© Wärtsilä
© Wärtsilä
Bolt line
Machine shop
Manufacturing technology developments projects (3)
Thermal/flow solver & stress solver
Project: Casting design
Project: Stress simulation
© Wärtsilä
H04647 (13.4 m2)
H04471 (1.1m2)
Project: Scanning of objects
H04471 (1.1m2)
H04471 (1.1m2)
Project: Reverse engineering
© Wärtsilä
Continuous Improvement
Summary WP technology development - focus
z Wärtsilä Propulsion focus points in development:
PL
M
ser
vi c
De
v
pro elop
du
ct
PL
M
Ma
nu
fa
ass cture
em
a
b le n d
© Wärtsilä
e&
mo
nito
rin
g
„
Hydrodynamics (supported by in-house Computational Fluid Dynamics
(CFD) technology)
„ Continued efforts to improve efficiency, reduce emissions
„ Cavitation, noise and vibration
„ Product innovation
„
Materials, casting technology and CAD/CAM/PLM technology
„ in-house production, machine-shop/foundry, of strategic parts
„ product- and process innovation
„
Mechanics and hydraulics
„ Product improvement and innovation
„
Mechatronics and control systems
„ Optimising in-service product performance
„ Create added value by optimisation
„
Product line completion/extension
„ Follow the market pro-actively which ships and propulsion systems
are needed
© Wärtsilä
Opportunities and challenges
z Several upcoming opportunities for advanced combinations of
our products
z Quality and lead-time are very important
z Sell on performance less on price
z Keep flexible in spite of workload
z No fear for new product & production developments
z Competition is active: we can not afford to stop developments
© Wärtsilä
© Wärtsilä
QUESTIONS ?
www.wartsila.com
[email protected]
© Wärtsilä