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© Wärtsilä
Manufacturing Technology Developments in Wärtsilä Propulsion
Fontys30 november 2006
by: André JanssenManager Manufacturing Technology & Tools
© Wärtsilä
Manufacturing Technology developments at Wärtsilä
• Company & organization• Product groups• Design aspects• Fixed Pitch Propeller production (movie)• Manufacturing Technology:
CAD, CAM, PLMBlade production line, CNC, roboticsHub part machining
• Technology Development projects:DesignManufacturing
• Conclusions and implications for the future
© Wärtsilä
Lips Since 1882
Our experience in ControllablePitch Propellers dates back to1903 when the Wichmancompany from Norway madeits first designs.
Ship Propellers
radar boat +/- 370
Bernoulli’s prop. 1770
Bramah’s prop. 1785
Edward Shorter 1803
Joseph Ressel 1829
Bennet Woodcroft 1832
Griffit 1849
Ericsson’s 1836
Hirsch 1860
Taylor 1907
© Wärtsilä
History
www. wartsila.com
• Dufay steel foundry at s’Hertogenbosch1925 Lips steel foundry at s’Hertogenbosch1934 Lips bronze foundry at Drunen (Max Lips president)1987 Lips (Investment organization)1998 TI-group John Crane-Lips2001 Smiths-group John Crane-Lips2002 Wärtsilä-group Wärtsilä-Propulsion-NL
© Wärtsilä
Wärtsilä operates in two markets
Ship Power and Service – growth through increased productrange and aquisitions
Power Plants – focus on the growing decentralized powergeneration market
Technological leadership
© Wärtsilä
Wärtsilä Organization
IMATRA (Steel) Ship Power Power Plants Service
Wärtsilä
Engine division
4 Stroke2 Stroke Propulsion Solutions
Seals & Bearing Propulsor Business W-Lips Defence W-Lips Inc.
USA/Pacific
Sales S&ASCPP ST-TT-WJFPP Controls Centralservices
Generalservices
© Wärtsilä
Ship Power
2004 presentation
Power Businessesnet sales
2005: 2,500.0
DID YOU KNOW THIS?Every third ship sailing the seas today has Wärtsiläequipment installed. This demonstrates our capability,commitment and the trust we enjoy amongshipbuilders and ship owners around the world.
Ship Power: 28%
Propulsor: 25%
© Wärtsilä
Ship Power businesses
Design
SolutionsPropulsion4-stroke2-stroke
Engineering
Project management
Commissioning
Lifetimesupport
Manufacturing
© Wärtsilä
Steerablethruster
Controls Bearings Seals
CPPFPPWaterjetsE-Pod thrusterTransversethruster
CIPS
Wärtsilä Propulsor products GearsEngines
© Wärtsilä
Wärtsilä Propulsion
FPP
Thruster/Jets
CPP
Segments
Brands
Segment structure
© Wärtsilä
Wärtsilä on map
R&DLicenceeSales
ProductionJoint Venture Production
ServiceRepresentatives
4-stroke, Delivery Centre Vaasa, FinlandAuxpac
Wärtsilä 20Wärtsilä 32
Wätsilä Vasa 32LNWärtsilä 32DFPropulsion, Rubbestadneset, Norway
CPP, Controls, Rudders and Reduction Gears
Propulsion, Drunen, The NetherlandsCPP, FPP, CIPS, Steerable Thrusters and Waterjets
Propulsion, Heerleen, The NetherlandsTransverse Thrusters
Propulsion, Havant, UKStrerntube Seals Face Type
Strertube BearingsLineshaft Bearings
2-stroke,Winterhur Swittzerland
4-stroke, deliveryCentre Trieste, Italy
Wärtsilä 26Wärtsilä 38Wärtsilä 46
Wärtsilä 46FWärtsilä 50DF
Wärtsilä 64Wärtsilä ZA40S
2-stroke, PolandH. Cegielski-poznan
2-stroke, Croatia3. Maj
Propulsion, Khopoli, IndiaReduction Gears
2-stroke, Shanghai, ChinaAuxpac
Wärtsilä 20
Propulsion, Zhenjiang, ChinaFPP
2-stroke, Taiwan China steelMachinery Corp.
2-stroke, China Hudong
Propulsion, Wuxi, ChinaTransverse Thrusters
2-stroke, JapanHitachi Zosen
2-stroke, JapanDiesel UnitedMitsubishiNKK
Propulsion, Toyama, JapanStrentube Seals Lip TypeStrerntube BearingsLineshaft Bearings
2-stroke, KoreaHyundai
Doosan Engine
2-stroke, chinaDalian
2-stroke, ChinaYichang
Head Quarters, Helsinki Finland
Biopower power plants, Kiuruvesi, Finland,BioEnergy thermal plantsOil and Gas boilers
© Wärtsilä
Drunen, the Netherlands
g 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
Wärtsilä Propulsor
© Wärtsilä
Market drivers
Current market requires:
Cost of equipment to be competitiveAt the same time guarantees on innovations have to be givenand products must be reliableDedicated solutionsShort lead timesExcellent fuel performance, low emissionsGood steering performance (ST)More accurate power response (CPP)Quiet propulsion systemsFleet and equipment monitoring
© Wärtsilä
Market drivers
Dynamic Positioning, thrust and reliability
Short berthing time
Weather routing, fuel optimisation and efficiency Noise, vibration and exhaust emissioncontrol
Auto-Docking &voyage optimisation
Low speed operations
Pitch governing
FPP
Operational performance
STT CPP
Operational cost
WJ
Environmental performance
Nozzles
Efficiencyrudder
TT
© Wärtsilä
With fixed pitch propellers the design will be optimised for one operationalcondition; 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
Use of patented material with proven outstanding mechanical and fatigue properties in seawater
One-stop-shop for total propulsion packages
26 - Wärtsilä Marine
Lips® Fixed Pitch Propellers
© Wärtsilä
Productgroup Fixed Pitch Propellers (FPP’s & CIPS)
Casted in one pieceApplication ships moving straightforwardDimensions from 0.4 till 12 meterdiameterNetto weight 11 kg till 94.600 kg(casted max.120000 Kg)Power from 500 kW till 80.000 kW
© Wärtsilä
World-class performance with regard to propellerefficiency, low noise, vibration levels and reliability.
Wake adapted high performance propeller designs Complete installations incl. shafting, hydraulics,
controls and accessories Robust mechanical designs Reliable and safe
Propeller blades of stainless steel or NiAl bronze
25 - Wärtsilä Marine
Lips® Controllable Pitch Propellers
© Wärtsilä
Productgroup Controllable Pitch Propellers (CPP’s)
Propeller with adjustable blades to reach the maximumpower during each condition
Application area ships who must be manoeuvrable
Dimensions till 9,8 m ( hubdiameter 2,8 m)
Largest power on an adjustable propeller is 44 MW
System consists shaft, hydraulic and electronic control
© Wärtsilä
Wärtsilä delivers steerable thrusters for offshore,sea going and tug applications in modular, retractableand underwater mountable designs
Tailored hydrodynamic designs based on wide experience with propulsion systems
Unique procedures and solutions available for mounting the thrusters underwater even in sea states
360º rotating for optimal manoeuvrability
High efficiency nozzles for improved performance
Available up to 7 MW
28 - Wärtsilä Marine
Lips® Steerable Thrusters
© Wärtsilä
Blue Marlin and Thialf
Thialf; Deepwater construction vesselOwner: Heerema ContractorsWärtsilä supply:
2x ST, each 5500 kW
Blue Marlin; heavy load vesselOwner: DockwiseWartsila supply:
2* ST type CS3500, each4500kW
© Wärtsilä
Lips® Jets
Market positionMajor supplier in the world
Market segmentsFast ferryNavyYachts
Unique Selling PointsState of the Art designLong life timeLow maintenance costsLightweight construction
Speeds up to 70 knots (130 Km/h)
© Wärtsilä
Typical examples of ships :Hybrid propulsion system
Trials 86m Yacht van LentContractual speed of 30 knots easily achieved (34 knots at full GTpower)
Waterjet : 1xLJ210E (23.000 kW)Props : 2xHigh Skew CP (2x4.640 kW)
© Wärtsilä
The Wärtsilä gears have been designed to meet the highest standards ofoperational efficiency, reliability, low noise and vibration.
Single input, single outputwith 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
24 - Wärtsilä Marine
Wärtsilä® Gears
© Wärtsilä
Wärtsilä delivers transverse thrusters for all differentkind of vessel types.
Controllable or Fixed Pitch Propeller
Robust and reliable design
Easy installation
Low noise versions
28 - Wärtsilä Marine
Lips® Transverse Thrusters
© Wärtsilä
Wärtsilä service concept and theworld wide network of more than5000 professionals in over 50 countries ensure thebest possible lifetime support.
International network of serviceand repair licensees
Service portfolio comprises: - training - technical support - field service - workshop and repair - upgrading and modernisation
S&AS Controllable Pitch Propellers
© Wärtsilä
Hydrodynamics
Tailor-made designsWake-adapted, highefficiencyLow noise and vibration levelNo cavitation erosionFull scale references
Design based on mission profileReduction of fuelconsumption
Match of propeller with engineIncreased reliability andlifetime
CFD (Computational FluidDynamics) calculations
Design for full scaleCo-operation with marine modeltest institutes
Independent and scientificsupport
State-of-the-art Design
© Wärtsilä
Historical development of maximum power applied per ship propulsor
0
10000
20000
30000
40000
50000
60000
70000
1800 1820 1840 1860 1880 1900 1920 1940 1960 1980 2000 2020Year
Power [kW]
Fixed Pitch Propellers
Controllable Pitch Propellers
Jets
Podded Propulsors
Ship power development
© Wärtsilä
Production Fixed Pitch Propellers
© Wärtsilä
Product Information/Management Systems … MSQ … BOM … EDM … INCLASS .. dig. ARCHIVE.. CAD ….. CAM … PDM … SAP
Projects/time/transformation
WP
- key
cus
tom
er/s
uppo
rt p
roce
sses
/peo
ple
Cha
n ge
ma n
a gem
ent
Business & Leadership Propulsor Systems
Today’s technical software challenges
Multi site (e
) vision
BOM’s DOCUMENTS DRAWINGS PARTS ASSY P
RODUCTS SOLUTIONS F
UNCTIONS KNOWLEDGE
© Wärtsilä
Vision on product structures & technical software
Integrated Product Data Structure Knowledge, file and application manager
“Standard”Applications:
ACADUGS-PLMMS-office……….
MODELSMATERIALS
CONFIGURATIONSKNOWLEDGE
PROJECTSREPORTS
Business Tools
TECHNICALDATABASE
SAP
Global-PDM
MechanicalEngineering Manufacturing PurchaseHydrodynamic
Design Sales Service
Processes
Wärtsilä Propulsor Business
DRAWING&
DOCUMENTARCHIVE
MSQSpecialApplications;
WVINP-WVBDUCTPROP
SPRESS………..
Third partyApplications:
PUFANSYS
VIEWCAST……….
© Wärtsilä
Vision on standard & special software multi site
Design-Engineering-
Applications/DATA
RequirementsRequirements Mech. engineering Workpreparation ProductionHydr. design
Manufacturing
Oracle (volume data)
Appl. Tech.dB … MSQ … BOM … EDM … INCLASS . dig.ARCH... CAD … CAM … PDM … SAP
Team Center (metadata)
TC TC TC TC
Collaborative desktop-design & manufacturing
Standard applications
Third party applications
Special applications:
.... ...hyd-mech-mfg
Knowledge
TC
Buy
Make
Foundries &
Machine shops
TC
Product Information/Management/Knowledge System
Oracle (volume data)
Development &
TC TC ? TC TC TC2SAP TC2MSQ
© Wärtsilä
Vision on NX-3D CAD master models and associativities
I S & VIn process Simulation and Verification
Database
Resources
NC-CodeShopdocs- operations- setup sheet
- toollist- nc-listing
I-man- NX1 = V8.1- V15 = V5.0
What HOW
Analyse
DataManagement
Automation - GRIP - UFUNC - TCL
FTNRobots
BNKSVRRABFCCPMBCFNCNKCMKDWHGKGKX
Automation- Ufunc
Fortranapplications
DNCFasysI-man web
Resources
- Tools - Fixtures - Machines - Controllers - Feeds - Speeds
methods
- Templates - Operations - Programs - Methods - Wizards - Proc. Assist. - shrinkage
3D NX4TC2005
CAD-Manufacturing CAD - Midtol
CAD-Blank CAD-nominal
CAD-AnalyseCAD-shrinkage
CAM-data plottersprinters
dBase
Quaestor- Ufunc CAD-Mastermodel-Associative-KDA-CAM extern
hydrodynamicdescription
2D
RS 6000
AS 400
PC LAN
propeller
parameters
Design (hydr.+ mech.)
- Cim sourceProductionKnowledge Fusion
MSQ
mechanicalpartdescription
Knowledge based Engin.
Custom
er needs
UG-Manager
When-Where
Product Data Infra Structure
ERP
ModelsConfigurations
?
Windows-XP
FEMCFD
© Wärtsilä
TeamCenter data associativity & management
3D Blank part3D blank part
3D eng. part
as-mfg.part
3D mfg. part-1
•Reverse Eng. part•Import eng. part
mfg. part-2
mfg. part-X
set-up-1
set-up-2
set-up-X
toolpaths/NC
Shopdoc
IS&V
NC
Shopdoc
IS&VNC
Shopdoc
IS&V
eng.libs.
SOLID
2D Drawingengineering
Assembly
associativity
Old method !
derived part/new part: links, copy, simlify, allowances, casting,block
mfg.libs.
As machined-1
As machined-2
As machined-x
IPW
“no facetted model “
set-up-as machinedNC
Shopdoc
IS&V
blank or ipw
part
fixture/tools
TC-ITEMdataset:
• workflow
• prt---------
shopdocs:
part-info
operation planset-up’s
tool list
general doc
ENGINEERING MANUFACTURING © Wärtsilä
NX, TC and SAP systems for WP-multi site
SAP (ERP)TC (PDM)
As-delivered
Standard /templates
As-engineered
As-built
Changerequests
CS Module
As-maintained
Engineering NB
Engineering S&AS
MM/PP Module
NX (CADCAM)
CAD
CAE
CAM
Other (250)WPNL-
applications
Oracle (volume)Fortran
Access
Design & Engineering Data Management (meta) Process Planning
© Wärtsilä
WP Drunen NL WP Norway WP Wuxi China
WP Web
WP Web Clients
WP Publication Server
TC TC TC
ViewingInfo
Work in Progress
Released Data
WAN-infonet2 mbps2 mbps
WEB clients
2 mbps
LAN
Wärtsilä propulsion multi site clusters
ODS= ObjectDistr. Server
© Wärtsilä
WPNL example parts, processes and tools
……………..
Manufacture and assemble
Developproduct
Free form parts/processes:• Workprep.Mfg. Progs. since 1960
• 3DCADCAM 1988
• Workprep.Mfg. Progs. CADCAM 1988
• CADCAM-NX2 2004
Solid parts/processes:• Workprep.Mfg. Progs. since 1960
• Manual CNC-programming since 1970
• 2DCAD 1983, 3DCADCAM 1988
• CADCAM-NX2 2004
© Wärtsilä
Example core parts Controllable Pitch Propeller
SOLID PARTS:
Hub cover
Blade carrier
Shaft
Sliding block
Moving cylinder yoke
Hub body
SOLID FREE FORM PARTS:
Blade surfaces
Edges
Fillet/blending
Bladefoot
© Wärtsilä
Free form parts & milling/finishing machines at Wärtsilä Drunen
• Milling & grinding robots
• 5-axis simultaneous milling machine
• Mobile measurement system, dedicated measuring machines
© Wärtsilä
Solid parts & milling-drilling- & turning machines at WärtsiläDrunen
• Horizontal- & vertical(carrousel) lathe machines
• Machining centers, Milling machines, Drilling machines,
• Laser cutting © Wärtsilä
solidification-simulation
manual grinding robot finish
photogrammetry
as-built information
NC-simulationmilling-grindingpaths
design geometry
robot milling
mould assy andpouring
5 axis simultaneous milling
mould-geometry
robot-simulation
2D machining
Design/Engineering/MFG.
Customer needs
Customer product
Integrated Product Data Structure Knowledge, file and application manager
Integrated Product Data Structure Knowledge, file and application manager
TO-BE production chain example for blades (blade line)
© Wärtsilä
CPP-blade design & work preparation
CAD blade model
CAD pattern model
CAD blade appl. program
© Wärtsilä
Robot grinding of EPS patterns
© Wärtsilä
EPS patterns
Sand moulds
Bronze
Blade line production : foundry
© Wärtsilä
Blade line production: key mfg. processes
Blade footmachiningcenter KB-
Skoda
Bolt-line
Bladegrinding
BL-manual
5 axesmachining
center BF-Kolb
BlademeasuringBM-Mora
RobotgrindingRA-ABB
PortableMeasurement
PM-Solo
© Wärtsilä
Schematic overview CAD, CAM, PDM
Tool paths. DEF. TCL. VNC
PC
PDM (database Teamcenter)
WH105-iTNC
CAMCAD
interactive template
stand.func.
automatedtemplate
postprocessor .VNC
.NC
.doc
PC
ASSY
postbuilder
shop data & docsUser Cycle
© Wärtsilä
3D CAD CAM, Product & Production set-up
© Wärtsilä
3D CADCAM for tooling design
© Wärtsilä
NC program and shopdoc generation
Automatic generation of: A=part info, B=tool list, C=set-up sheets, D=simulation, E=NC data file
A
E
D
C
B
© Wärtsilä
Simulation NC machining prismatic & free form parts
© Wärtsilä
Design technology development projects
Oil temp. (viscosity), additives, water, particles
Accelerations
Envelope Vibrationspectra
Oilstate
Data fusion (fuzzy based)
Advanced CBM data
DecentralisedSystem
PitchAzimuth
RPM
To / from ships’ network (fieldbus)
Project: Health monitoring
Project: Propeller efficiency measurement
Project: Rudder efficiency 5-10%
Project: Material improvement
Project: Contra rotating propeller efficiency 10-17%
Project: 3S Energy
© Wärtsilä
Manufacturing technology development projects (1)Project: milling versus grinding
Project: shrinkage knowledge Project: Meten=Weten
Project: CAM-TC structures/data
© Wärtsilä
Manufacturing technology development projects (2)
Project: Hub component line (total machining)
Machine shop
Bolt line
Blade line
© Wärtsilä
Manufacturing technology developments projects (3)
Project: Reverse engineering
Project: Stress simulationProject: Scanning of objects
Project: Casting design
© Wärtsilä
Thermal/flow solver & stress solver
H04
471
(1.1
m2)
H04
471
(1.1
m2)
H04
471
(1.1
m2)
H04
647
(13.
4 m
2)
© Wärtsilä
Continuous Improvement
Manufacture and assemble
Developproduct
PLM service & monitoring
PLM
© Wärtsilä
Summary WP technology development - focus
Wärtsilä Propulsion focus points in development:
Hydrodynamics (supported by in-house Computational Fluid Dynamics(CFD) technology)
Continued efforts to improve efficiency, reduce emissionsCavitation, noise and vibrationProduct innovation
Materials, casting technology and CAD/CAM/PLM technologyin-house production, machine-shop/foundry, of strategic partsproduct- and process innovation
Mechanics and hydraulicsProduct improvement and innovation
Mechatronics and control systemsOptimising in-service product performanceCreate added value by optimisation
Product line completion/extensionFollow the market pro-actively which ships and propulsion systemsare needed
© Wärtsilä
Opportunities and challenges
Several upcoming opportunities for advanced combinations ofour products
Quality and lead-time are very important
Sell on performance less on price
Keep flexible in spite of workload
No fear for new product & production developments
Competition is active: we can not afford to stop developments
© Wärtsilä
© Wärtsilä
QUESTIONS ?
www.wartsila.com