Kranendonk Shipbuilding

�� is the robot technology centre

for non-repeti ti ve producti on.

Improve your process and producti vityRoboti cs for shipyard automati on

Demand for technological innovati onsFocus in shipbuilding shift s to qualitati ve upgrading, rather than quanti tati ve expansion. New regulati ons and requirements put pressure on shipyards and their technological development. To cope with these challenges, there is a strong demand for technological know how and innovati ve soluti ons.

Linking design and producti onInnovati ons in the shape and functi onality of ships demand for technological developments in shipbuilding. For example, new hull designs require special att enti on in assembly. The soluti on for the producti on of complex designs is 3D ��. By linking the 3D �� design and the actual producti on with intelligent soft ware, highly accurate constructi ons can be achieved.

Macro economical developments have a major impact on the

shipbuilding industry. Global powers are shift ing and government

subsidies are infl uencing competi ti on. New regulati ons are putti ng

pressure on yards. The industry is further infl uenced by innovati ons in

hull design and new vessel types.

Innovati on brings a new edge to shipbuilding

Requiring complex hull shapes to the mm accurate

Facing our global challenges together

2 �� Smart roboti cs

Early container ship (1956)

Full Cellular (1970)

Panamax (1980)

Panamax Max (1985)

Post Panamax (1988)

Post Panamax Plus (2000)

New Panamax (2014)

Triple E (2013)

Shipbuilders must keep upTo cope with the never ending search for bigger vessels, shipyards are looking for new ways in extreme engineering. This puts a strain on constructi on. For example, secti ons of the ship need to be welded with high precision and all welds have to be consistent. A perfect job for robots.

Labour cost is the key determinantShipyards have to invest in their producti on and are seeking ways to reduce producti on costs. Labour cost is a determining factor when it comes to a yard's cost competi ti veness. Also, skilled labour becomes increasingly hard to fi nd. Thus, att enti on goes to effi ciency improvements in shipbuilding. Automated producti on and robots off er a soluti on for shipbuilders to stay competi ti ve.

Special purpose vessels demand producti on fl exibilityShipyards are confronted with a demand for new vessel types. Platf orm Supply Vessels and related vessels types are challenging ship designers. Shipyards are combining skills to cope with the great loads that these ships need to carry. The producti on of these vessels comes with new challenges and calls for a fl exible producti on environment.

A combinati on ofskills to meet increasing demands

Getti ng bigger and bigger: extreme loads

Improve effi ciency in shipbuilding

3 Shipyard automati on by ��

Cutti ng edge innovati onThe Robot Technology Centre

Smart roboti csTraditi onally, industrial robots are used for repeti ti ve tasks. We develop sensors and soft ware that make our robots smarter. It means we can automate non-repeti ti ve producti on processes. This unique competence opens a world of opportuniti es for manufacturers. We use our skills to build fully automated producti on shops, where all processes are integrated and aligned.

Cutti ng edge technologyOur wide knowledge on roboti c automati on makes us excellent problem solvers. We assist you from an early stage, to create an opti mal producti on fl ow for your yard. This way, we jointly create a tailored automati on plan that raises producti vity and saves costs. The culture for innovati on within �� makes sure we always deliver cutti ng edge technology at the highest level.

25 Years of Making a Diff erenceFor more than 25 years, �� has modern-ized shipyards at the highest level. Key milestones have been:

1987: Delivery of the fi rst robot for profi le cutti ng.1993: First robot welding system for web welding.1996: The cutti ng robot gets integrated with other processes, like cleaning and marking. 2000: Delivery of a total profi le factory that cuts over 3 km of profi les per day, all centrally controlled.2003: Introducti on of the intelligent RinasWeld soft ware, for 'hands-off robot programming'. 2005: Eight robots can jointly weld one panel, and smartly distribute their tasks.2010: Revoluti on in the pipe shop, by applicati on of roboti cs, storage and producti on control soft ware.2013: The Edge Preparati on System off ers a smart way to comply to the IMO PSPC regulati ons.

�� is the robot technology centre for non-

repeti ti ve producti on. We make robot systems suitable

for non-repeti ti ve tasks, by developing smart sensors and

soft ware. �� can maintain a Technology Centre

positi on by simultaneously being an engineer, supplier,

supporter and partner, and connecti ng to all stakeholders.

Supplier

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Supporter

Partner


‘Being fanati c in robot engineering’‘At ��, we use clear methods when designing new robot applicati ons. Whether it's a specialized welding tool or a soft ware interface, our way of work-ing is characterized by an approach we call Triple C. The fi rst C is for Constructi on. Creati ng a rigid constructi on that handles a harsh producti on environment is the main requirement. Secondly, Calibrati on makes sure our systems are extremely accurate. By applying soft ware correcti ons, we make a robot more accurate that it can physically be. Lastly, Controls are being developed. We use smart soft ware to enable easy opera-ti on of the machines. In any new develop-ment process, we pay att enti on to every detail. You can call us fanati cal about this.’

Evert GeurtsenTechnical [email protected]

Shipbuilding is all about producti on fl owproducti on fl ow

Welding of assemblies is a perfect job for robots

Automati ng key parts in the process chainIn shipbuilding, it is all about the producti on fl ow. Processes have to be aligned as raw steel plates are turned into giant vessels. The challenge is to keep the fl ow running, while maintaining a ti ght grip on building quality.

The shipbuilding process is one of the most complex constructi on jobs created by man. All producti on processes that run separately have their respected challenges. Since 1987, �� is the leading technology supplier for advanced roboti cs in shipbuilding. We off er advanced roboti c systems to automate key parts in the process chain.

In the process we focus on:Profi le and cutti ng shops (step 2) By linking all sys-tems, we improve your fl ow and realize large cost savings. Smart storage and just-in-ti me delivery cre-ates an eff ecti ve cutti ng shop. Assembly and welding shops (step 3) Welding of webs, panels and 3D secti ons is a perfect job for robots. Controlling them is the challenge, so we focus on data fl ow and intelligent soft ware tools. It saves manual welding and improves producti on quality.Pipe shop (step 5) By roboti zing the pipe shop, the producti on ti me for each pipe goes from hours to minutes. Major cost savings are realized by our inte-grated soluti on.

2 Cutti ng shops Profi le Processing (page 10)Edge Preparati on System (page 11)

4 Secti on assembly Joining of sub-assemblies

3 Assembly and welding shopsDouble Hull Welding (page 12)Panel Welding (page 12)Web Welding (page 12)


Total profi le processingsoluti ons

‘Keeping your fl ow running’‘As customer support manager, it is my goal to maintain the highest possible producti vity of your �� equip-ment. We off er a full pack of services to do so. Our support engineers regularly visit your yard for inspecti ons and performance tests. This way, we keep you producti vity high and reduce downti me to a minimum. Also, we train your operators and mainte-nance crew. In this way, we improve your fl ow and keep it running.’

Werner Smeiti nkManager Customer Support

HelpdeskHolland +31 344 655 443Japan +81 832 425 [email protected]

Major cost savings by roboti zingMajor cost savings by roboti zingthe pipe shop

Edge Preparati on System to comply with IMO PSPC

5 Pipe Shop 5 Pipe Shop 5 Pipe Shop 5 Pipe Shop 5 Pipe Shop 5 Pipe Shop 5 Pipe Shop 5 Pipe Shop Roboti c pipe shop (page 14)

6 Module outf itti ng Prepared tubes are mounted

7 Ship assembly At the dock

1 Input raw materials Steel plates and profi les


Setti ng the right course for the futureExplorati on of deepwater oil fi elds is increasingly economically viable. It results in more operati ons in remote areas. The Seven Oceans has been developed to perform pipe laying operati ons in these areas, where conditi ons are tough. Despite its compact design, the vessel has a high payload and excellent seakeeping charac-teristi cs. �� Merwede shipyard – a long term customer of �� – launched the Seven Oceans in 2010.

Photo courtesy IHC Merwede



Integrati ng logisti cs for the perfect fl owIntegrati ng the logisti cs around profi le processing increases producti vity and fl ow. A fully equipped plant features a range of components: cutti ng cells, logisti cal equipment and dedicated producti on soft -ware. We deliver all soft ware and hardware to build such a shop, realizing just-in-ti me producti on.

The cutti ng lines can be equipped with roller con-veyors and infeed and outf eed buff ers for tempo-rary profi le storage. Additi onally, high-rise storage systems can be placed before and aft er the system. This results in an opti mal producti on fl ow.

Highest quality componentsA key component in the profi le processing shop is the �� 600 cutti ng cell. The cutti ng cell is based on our standardized �� concept. All electrical and measuring components are integrated into the rigid base frame, resulti ng in a durable cutti ng system that withstands a harsh shipbuilding environment.

The producti on soft ware adapts the cutti ng path to the actual dimension of each profi le, so the highest accuracy is achieved. By setti ng up a direct CAD interface, your work preparati on ti me is reduced to almost zero.

Effi cient profi le processing is important for a shipyard. The focus should be on creati ng a perfect fl ow, where all machines are synchronized with planning and stock. �� connects all machines into one soluti on.

High speed plasma cutti ng forincreased throughput

All operati ons (e.g. cutti ng, marking, grinding) in the cutti ng cell

Profi le cutti ng line with infeed storage

Maximizing fl ow by integrati ng all processesComplete soluti ons for profi le processing


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'We maximize your output by realizing a perfect producti on fl ow'‘Over the past 30 years we have delivered dozens of profi le cutti ng lines to shipyards all over the world. Our success is based on the competence to integrate all related processes into one complete soluti on that is centrally controlled. It means that one man runs a complete profi le cutti ng shop. The most advanced profi le shops can cut more than 3 km of profi les per day. With these advanced systems, you can save heavily on labour costs and maximize your output per square meter of shopfl oor.’

Jelle JanssenSales [email protected]

Milling a constant radiusTo improve the quality of coati ngs in shipbuilding, �� demands the preparati on (rounding) of plate edges. Automati on of this process requires an adapti ve machine that perfectly follows plate contours. The Edge Preparati on System combines proven �� technology with a state-of-the-art force controlled milling system. The system machines controlled milling system. The system machines both sides without turning of the plate. Advanced both sides without turning of the plate. Advanced soft ware with a touch interface makes sure that soft ware with a touch interface makes sure that soft ware with a touch interface makes sure that operati on is easy.

Edge Preparati on System

Adapti ve milling technology: constant force around contours

Soft ware to control the producti on fl ow The �� producti on soft ware takes care of a conti nuous producti on fl ow, controlling the logisti cs as well as additi onal machines. logisti cs as well as additi onal machines.

IMO PSPC compliant edge preparati on


Challenges in constructi onShip panels, webs and block secti ons demand consistent and high precision welding. These sub-assemblies are one-of-a-kind operati ons with many hard-to-reach spots. ��'s welding robots can reach these diffi cult places and make opti mal use of the available space, with no collisions.

Automati on for 'one-off s'Welding in shipbuilding is non-repeti ti ve, mean-ing that the programming has to be automated. �� off ers a soft ware soluti on called RinasWeld, which is the most advanced producti on tool for welding robots available. Also, we off er easy to use shopfl oor interfaces for direct data entry.

Roboti c panel and web weldingWhether it is about large panels, micro panels or webs, ��'s travelling gantries off er the most fl exible soluti on. Our panel and web wel-ding systems support one, two or four robots. The robots simultaneously weld and smartly distribute tasks between them. The rigid design of the gantries ensures extreme stability and high quality welding.

Double hull welding with ti ny robotsWelding the double hull of a ship is diffi cult because of the limited space. Our Double Hull Welding Gantry performs automated robot welding of these secti ons. Tiny robots on extendable sti cks can manoeuvre into the smallest spaces of the blocks.

Coping with the complexity of designs‘Hands-off ’ roboti c welding soluti ons

Eight robots automati callyworking together

Welding in shipyards comes with specifi c challenges to cope with the complexity of the designs. ��’s robot welding soluti ons can handle conti nuously changing designs, by using advanced soft ware tools.

1st price: Mariti me Innovati on Award for our Panel Welding Gantry with RinasWeld soft ware


Panel Welding GantryPanel Welding Gantry

Direct data entry at the shopfl oorDirect data entry gives the operator the ability to control the system by entering parameters. This way, the operator does not require knowledge about robot programming. It makes operati on easy. Depending on the complexity of the products, the robots can be programmed by direct data entry at the shopfl oor, or by importi ng of 3� �� models. We have the most fl exible soluti on for your yard.

The sophisti cated RinasWeld soft wareFor complex assemblies, �� off ers the world's most sophisti cated robot programming soft -ware: RinasWeld. This soft ware prepares the pro-ducti on tasks in the offi ce, by using 3� �� data of the product. RinasWeld gives maximum fl exibility, as all programming tasks are performed automati -cally. RinasWeld balances the work load between multi ple robots to maximize producti vity.

Easy shopfl oor control with touch interface

The soft ware generates collision free robot paths

Double Hull Welding GantryWeb Welding Gantry

Small robots reach insidedouble hull secti ons


A unique automati on soluti on for shipyardsThe producti on of pipe spools is a true craft sman's job. Flanges have to be welded to the tubes within strict tolerances. The process is hard to automate, but we off er a unique soluti on that does the job. All processes are integrated and centrally controlled, to create the fi rst roboti c pipe shop in the world.

From 4 hours to 8 minutes producti on ti meThe roboti c pipe shop is the result of a thorough analysis of the producti on of pipe spools in the ship-building industry. The roboti zed pipe shop brings the producti on ti me for a pipe spool back from 4 hours to 8 minutes. The central control system takes care of the producti on fl ow and monitors each tube individually.

Fully automated from infeed to bendingThe pipes go from the storage through a sawing machine. Aft er sawing, rest material is fed back into the storage. Next, the pipe is grinded, to maximize welding quality. Four robots mount and weld the fl anges to the pipes. Then, the pipes are ready to go to the bending lines. Bending of the pipes is done with the fl anges att ached. All these steps make sure that the pipe shop reaches high capacity and quality.

Capturing craft smanship in the future pipe shop The roboti c pipe shop

Accurate fl ange assembly and welding

To the bending lines


'We revoluti onize the pipe shop''Manufacturing pipe spools is a skilful job. Welders are trained to mount the fl anges within ti ght tolerances. We found that it is truly a craft sman's job, which made it challenging to automate. During the development of the roboti c pipe shop, key parts of the fl ow were changed. Now, the fl anges are mounted before the tubes are bent. When we installed the fi rst roboti c pipe shop, we used the welder's knowledge to fi ne-tune the system. Their craft smanship has been translated into a smart robot system, that revoluti onizes the traditi onal pipe shop.'

Richard PolderProject [email protected]

All tube sizes in any order, givefl exible producti on

Fully automated logisti cs with intermediate output

Smart storage system with sideways infeed and waste reducti on functi onality


�� is the robot technology centre for non-repeti ti ve producti on. By implementi ng intelli-gent robot technology, we enable manufacturers to produce more effi ciently and eff ecti vely. We supply custom build soluti ons that are cleverly integrated into material and data fl ows.

�� was founded in 1983. We started our company as a supplier of custom automati on systems for industrial applicati ons. Over the years we have specialized in advanced roboti cs for heavy steel applicati ons. Today we off er an innovati ve approach that creates a range of automati on oppor-tuniti es for manufacturing companies.

In the near future we see technological and macro-economical developments putti ng pressure on the producti on process. Advanced automati on is spreading into new areas. Integrated process and centralised operati ons are decisive factors in choos-ing the right equipment. �� will keep assisti ng companies in transforming their produc-ti on processes to make them more effi cient, fl exible and ready for the future.

www.kranendonk.com

Contact informati on

Kranendonk Producti on Systems ��(headquarters)

Phone +31 344 623 944Fax +31 344 623 388

P.O. Box 6147��-4000 �� TielThe Netherlands

[email protected]

��

Sir Rowland Hillstraat 10��-4004 �� TielThe Netherlands

v 07 2013

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Kranendonk Shipbuilding