1 Innovation aid Berufsbildung

Transcription

1 1 Innovation aid Berufsbildung

2 Innovative prototype development CELEBRITY SOLSTICE 1/2 Innovative prototype of a series of four cruisevessels for CELEBRTIY CRUISES, Miami Main dimension: GT - total length: 317,20 m - breadth: 36,80 m - passenger capacity: key facts: - total cost for the ship: above 500 m - eligible costs: ~ 12,9 m - innovation aid (20 %): ~ 2,5 m - prototype handing over to owner:

3 Innovative prototype development CELEBRITY SOLSTICE 2/2 List of important innovative individual elements: - Subdivision calculated under the new damage calculation based on probabilistic approach - Optimization of the design after design criteria such as: - Safety und Redundancy - Operational Efficiency and Energy Savings - Environmental Protection - Lifecycle Management - Development and construction of an extremely compact exhaust casing - Design and installation of projecting lifeboats - Fire zone size exceeded the limits set by SOLAS (risk assessment) - Development and construction of a revised concept for the air conditioning of public spaces - Design, planning and construction of a theater with 1,200 seats -New configuration of the passenger cabins (interlocking system) - Design and construction of a hull and a propulsion system for speed of 24 knots at 15% sea margin - Reduction of energy consumption for the total ship operation by 30%

4 Innovative prototype development CLIPPER HEBE 1/2 Innovative prototype of a series of four LPG/LEG tankers for the Norwegian shipping company Solvang ASA Main dimension: - tank volume: m³ - total length: 154,90 m - breadth: 22,70 m key facts: - total cost for the ship: above 50 m - eligible costs: ~ 1,5 m - innovation aid (20 %): ~ 0,3 m - prototype handing over to owner:

5 Innovative prototype development CLIPPER HEBE 2/2 List of important innovative individual elements: - Development of a new design with a new hull shape and a volume of m³ LEG / LPG instead of m³ m³ - Weight, intact and damaged stability calculation - new design of the tank, gas, loading and unloading system - Implementation of green ship principle - 2 deck tanks - Waste incineration, grey and black water treatment - Extension of the list of gases to be transported

6 Innovative prototype development DISNEY DREAM 1/2 Innovative prototype of a series of two cruise vessels for DISNEY CRUISE LINE, Orlando Main dimension: GT - total length: 339,80 m - breadth: 37,00 m - passenger capacity: key facts: - total cost for the ship: above 600 m - eligible costs: ~ 18,8 m - innovation aid (20 %): ~ 3,7 m - Scheduled handing over to owner:

7 7 Innovative prototype development DISNEY DREAM 2/2 List of important innovative individual elements: - Family cabins with a width of 2880 mm and a length of mm each cabin - Pools and water play areas especially design for children with special sanitation and safety requirements - Entertainment according to the specifications of an entertainment park operator - Outline of the vessel in accordance with a classic Atlantic liner under application of round shaped superstructures and glazings - Design and manufacturing of artificial funnel out of light weight materials, used as public rooms - Standardization of service pantries - Increase capacity of the lifeboats up to 270 people per boat - Improved maneuverability due to the use of rudder fins - Increase of environmental protection by preventing the spill of oil due to water lubricated shaft bearings - Improving fire safety through new layout of engine room - Improved operation manuals for operation, error analysis and procurement of supplies and spare parts

8 Innovative process Profile welding device for light weight construction 1/2 Innovative manufacturing process for fillet welds in lightweight construction using laser hybrid technology in a panel line key facts: - eligible costs: ~ 10,5 m - innovation aid (20 %): ~ 2,1 m - increase of productivity: + 25 % - improvement of the efficiency of vessel: - ship becomes lighter fuel savings - improved interior of the ship selling point - improvement of the efficiency of production: - less straightening despite reduced thicknesses - possibility of coil sheet metal processing - possibility of the revised structural design - possibility of building larger sections

9 9 Innovative process Profile welding device for light weight construction 2/2 List of important innovative individual elements: - Reduced distortion - Manufacturing of plates and profiles up to 30 meters width, thus larger panel surfaces per time unit producible - Improved welding head with better accessibility and seam tracing with adaptive process control - Reduction of distance between the profiles to 120mm and profile size to 4 x 40mm - Adjustment of clamping pressure for processing of sheet metal coil - Software extension (conversion to the new processes by modified or additional modules)

10 Innovative process Single side welding device with disc laser for light weight construction 1/2 Innovative manufacturing process for butt welds in lightweight construction using laser hybrid technology in a panel line key facts: - eligible costs: ~ 20,8 m - innovation aid (20 %): ~ 4,2 m - increase of productivity: + 25 % - improvement of the efficiency of vessel: - ship becomes lighter fuel savings - improved interior of the ship selling point - improvement of the efficiency of production: - less straightening despite reduced thicknesses - increased welding speed - lower energy consumption due to higher efficiency of the laser source - possibility of the revised structural design - flexibility for thick plate processing - possibility of building larger section

11 Innovative process Single side welding device with disc laser for light weight construction 2/2 List of important innovative individual elements: - Thicknesses of less than 5mm - Higher welding speed and less distortion - Wider sheets up to 30 m, thus larger panel surfaces per time unit producible - Improved welding head with better accessibility and seam tracking with adaptive process control - Device for application of the tandem-welding process for thick plates - Adjustment of security measures to the new laser beam characteristics - Simplified routing and transport technology - Adjustment of clamping pressure for processing of sheet metal coil - Software extension (conversion to the new processes by modified or additional modules)

12 12 Innovative process Flexible manufacturing cells for the completion of vessel size equivalent section sizes in thin sheet metal construction 1/2 Production cycle oriented assembly of prefabricated sub-assemblies with different work content of a steel section. The sections are larger compared to common shipbuilding practice and consist of remarkable plate thickness variation. The result is a quality controlled manufacturing steel section to 160 tons key facts: - eligible costs: ~ 11,6 m - innovation aid (20 %): ~ 2,3 m - increase of productivity: + 25 % - improvement of the efficiency of production: - core competence focuses on assembly and welding solid construction sites - halving of the usual shipbuilding turnaround time by means of a flexible factory process - in stock manufacturing special congestion control (Just In Time) - use of optimized production and joining methods for generating a higher quality welding

13 13 Innovative process Flexible manufacturing cells for the completion of vessel size equivalent section sizes in thin sheet metal construction 2/2 List of important innovative individual elements: - Section lifting device for the assembly of bulwarks, lifting eyes and free-form contours - Integrated transportation system for the preparation of robotic welding stations with laser hybrid welding for sheets up to a width of 30m and a thickness of 3mm - New high-performance welding process for shipbuilding unusual combinations of sheet thickness 3-20mm and a long suture lines (30m) in all welding positions (eg, vertical welding seams) - Fully mechanized use in manual welding technology environment - Clock time controlled production processes at very different work content on the components

14 14 Innovative process Production-demand-oriented, group- and system comprehensive provision of information to shipbuilding steel components 1/2 Equipment and accommodation information as well as processing lines can be applied to the steel plates already on the panel line key facts:- - eligible costs: ~ 4,7 m - innovation aid (20 %): ~ 0,9 m - increase of productivity: + 25 % -improvement of the efficiency of production: - time-consuming measurement work is saved for subsequent work processes the measured work becomes easier resp. - reduction of overall lead time of shipbuilding production process - improvement in quality of installation - improvement of welding quality

15 15 Innovative process Production-demand-oriented, group- and system comprehensive provision of information to shipbuilding steel components 2/2 List of important innovative individual elements: - Coordination and connection of drawing information from the three main areas steel, engine and outfitting/ accommodation - Adaptation of the existing machines and their work and travel resp. - Integration of new NC-cutting machines with appropriate marking and grinding equipment etc. for 30m sections - Marking stations for mutual applying and finishing of the components, taking into account the high tolerance requirements - Processing of the higher labor content in the same time unit

16 16 Innovative process Flexible robot - profile- cutting - production - line including integration into automated manufacturing systems 1/2 The line is embedded in a fully automated road and processes usual ship and special profile types. At the same time long profiles with high accuracy requirements will be treated. An overall master control coordinates the production cycle for the simultaneous supply of the connected automated production lines and manual removal points key facts:- - eligible costs: ~ 4,8 m - innovation aid (20 %): ~ 0,9 m - increase of productivity: + 25 % - improvement of the efficiency of vessel: - Use of special profiles and small profiles allow greater design freedom of the designer, thus more light weight construction and availability of space. - improvement of the efficiency of production: - reduction of manual cutting operations, particularly for special profiles. - reduction of lead times of ships. - reduction of internal transport operations by direct connection of the production lines. - reduced expenses in the material composition - transparent, value-oriented current flow production.

17 17 Innovative process Flexible robot - profile- cutting - production - line including integration into automated manufacturing systems 2/2 List of important innovative individual elements: - Master control for parallel production of light and heavy weight products. - Master control, connection of multiple processing lines. - Control and availability with regard to the second cycles. - Extension of commercially available blasting to 3 NC-controlled jets, two of which are adjustable in angle and one in a plane. - Hydraulic gripper detects the edges of the profile and the profiles transported through the cutting chamber with higher accuracy and repeatability. - Synchronization of the main axis of the feeder carriage with the robot axis and usage during the cutting process as additional robot axis. - Fixed marking station with moving work piece, marking from below. - Slip free conveyor belt over a transport distance of 240m - combination of several rotating roller guides for turning of long profiles - commissioning of 30m instead of 20m long profile strands.