Manufacturing Technology developments at Wärtsilä

• Company & organization

• Product groups
Manufacturing Technology Developments in Wärtsilä Propulsion • 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
Fontys
30 november 2006 • Conclusions and implications for the future
by: André Janssen
Manager Manufacturing Technology & Tools

© Wärtsilä © Wärtsilä

Ship Propellers History

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.
• Dufay steel foundry at s’Hertogenbosch
1925 Lips steel foundry at s’Hertogenbosch
1934 Lips bronze foundry at Drunen (Max Lips president)
radar boat +/- 370 Bennet Woodcroft 1832
1987 Lips (Investment organization)
Bernoulli’s prop. 1770 Griffit 1849
Bramah’s prop. 1785 Ericsson’s 1836
1998 TI-group John Crane-Lips
Edward Shorter 1803 Hirsch 1860 2001 Smiths-group John Crane-Lips
Joseph Ressel 1829 Taylor 1907 2002 Wärtsilä-group Wärtsilä-Propulsion-NL
© Wärtsilä © Wärtsilä
 Wärtsilä operates in two markets Wärtsilä Organization

Wärtsilä

IMATRA (Steel) Ship Power Power Plants Service Engine division

2 Stroke 4 Stroke Propulsion Solutions

Propulsor W-Lips Inc.

Seals & Bearing W-Lips Defence
Business USA/Pacific

„ Ship Power and Service – growth through increased product

range and aquisitions
„ Power Plants – focus on the growing decentralized power Sales CPP FPP ST-TT-WJ Controls S&AS
Central
services
General
services
generation market
„ Technological leadership

© Wärtsilä © Wärtsilä

Ship Power Ship Power businesses

Design
Ship Power: 28%
Power Businesses Engineering
net sales Propulsor: 25%
2005: 2,500.0
Manufacturing

Project
management
DID YOU KNOW THIS?
Every third ship sailing the seas today has Wärtsilä
equipment installed. This demonstrates our capability, Commissioning
commitment and the trust we enjoy among
shipbuilders and ship owners around the world.
Lifetime
support

2-stroke 4-stroke Propulsion Solutions

2004© Wärtsilä
presentation © Wärtsilä
 Wärtsilä Propulsor products Segment structure
Wärtsilä Propulsion
Controls Engines Gears Bearings Seals

Segments

Brands
FPP

Thruster/Jets

Transverse Steerable E-Pod thruster Waterjets FPP CIPS CPP CPP

thruster thruster

© Wärtsilä © Wärtsilä

Wärtsilä on map Wärtsilä Propulsor

4-stroke, Delivery Centre Vaasa, Finland
Auxpac
Wärtsilä 20
Wärtsilä 32
Wätsilä Vasa 32LN
Biopower power plants, Kiuruvesi, Finland,
BioEnergy thermal plants
Drunen, the Netherlands
Oil and Gas boilers
Propulsion, Rubbestadneset, Norway Wärtsilä 32DF
CPP, Controls, Rudders and Reduction Gears

Propulsion, Drunen, The Netherlands Head Quarters, Helsinki Finland

CPP, FPP, CIPS, Steerable Thrusters and Waterjets
Propulsion, Toyama, Japan
Propulsion, Heerleen, The Netherlands Strentube Seals Lip Type
Transverse Thrusters
Propulsion, Havant, UK
2-stroke, Poland
H. Cegielski-poznan Strerntube Bearings
Lineshaft Bearings
g Wärtsilä Propulsion Netherlands B.V.
Strerntube Seals Face Type
Strertube Bearings 2-stroke, Korea
Lineshaft Bearings 2-stroke, Croatia Hyundai
3. Maj Doosan Engine
2-stroke,
Winterhur Swittzerland 2-stroke, china
2-stroke, Japan
Diesel United
g Operational Center Of Excellence for:
4-stroke, delivery
Centre Trieste, Italy
Dalian

2-stroke, China
Mitsubishi
NKK - CPP
Wärtsilä 26
Wärtsilä 38
Yichang

2-stroke, Japan
- FPP & CIPS
2-stroke, Shanghai, China
- Steerable Thrusters & Waterjets
Wärtsilä 46 Hitachi Zosen
Wärtsilä 46F Auxpac
Wärtsilä 20 Propulsion, Wuxi, China
Wärtsilä 50DF
Transverse Thrusters
Wärtsilä 64
Wärtsilä ZA40S 2-stroke, China Hudong
2-stroke, Taiwan China steel
Machinery Corp. g Machine shop and foundry
Propulsion, Zhenjiang, China
FPP

Propulsion, Khopoli, India

Reduction Gears g System Integration
Production
Joint Venture Production
R&D
g ± 600 employees
Licencee
Sales
Service
Representatives

© Wärtsilä © Wärtsilä
 Market drivers Market drivers

Operational cost Environmental performance

z Current market requires: FPP

„ Cost of equipment to be competitive

„ At the same time guarantees on innovations have to be given Weather routing, fuel optimisation and efficiency Noise, vibration and
and products must be reliable exhaust emission
„ Dedicated solutions control
Efficiency
„ Short lead times
rudder
„ Excellent fuel performance, low emissions
„ Good steering performance (ST) Low speed operations Operational performance
„ More accurate power response (CPP)
„ Quiet propulsion systems Nozzles Auto-Docking &
„ Fleet and equipment monitoring voyage optimisation
Dynamic Positioning, thrust and reliability Pitch governing

Short berthing time

TT STT CPP WJ
© Wärtsilä © Wärtsilä

Lips® Fixed Pitch Propellers Productgroup Fixed Pitch Propellers (FPP’s & CIPS)

z Casted in one piece

With fixed pitch propellers the design will be optimised for one operational z Application ships moving straight
condition; achieving superior propeller efficiency. forward
z Dimensions from 0.4 till 12 meter
; State of the art propeller design resulting in high propeller efficiencies diameter
and low pressure pulses z Netto weight 11 kg till 94.600 kg
(casted max.120000 Kg)
; More than a century of experience in z Power from 500 kW till 80.000 kW
propeller design and manufacturing

; Use of patented material with

proven outstanding mechanical
and fatigue properties in seawater

; One-stop-shop for total

propulsion packages

© Wärtsilä
26 - Wärtsilä Marine © Wärtsilä
 Lips® Controllable Pitch Propellers Productgroup Controllable Pitch Propellers (CPP’s)

z Propeller with adjustable blades to reach the maximum

World-class performance with regard to propeller power during each condition
efficiency, low noise, vibration levels and reliability.
z Application area ships who must be manoeuvrable
 Wake adapted high performance propeller designs
z Dimensions till 9,8 m ( hubdiameter 2,8 m)
 Complete installations incl. shafting, hydraulics,
controls and accessories z Largest power on an adjustable propeller is 44 MW

 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, z Blue Marlin; heavy load vessel
sea going and tug applications in modular, retractable z Owner: Dockwise
and underwater mountable designs 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 z Thialf; Deepwater construction vessel
sea states
z Owner: Heerema Contractors
; 360º rotating for optimal manoeuvrability z Wärtsilä supply:
„ 2x ST, each 5500 kW
; High efficiency nozzles for improved performance
; Available up to 7 MW

© Wärtsilä
28 - Wärtsilä Marine © Wärtsilä
 Lips® Jets Typical examples of ships :Hybrid propulsion system

„ Market position
„ Major supplier in the world
z Trials 86m Yacht van Lent
„ Contractual speed of 30 knots easily achieved (34 knots at full GT
„ Market segments power)
„ Fast ferry
„ Navy
„ Yachts

„ 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 : 1xLJ210E (23.000 kW)

Props : 2xHigh Skew CP (2x4.640
kW)

© Wärtsilä © Wärtsilä

Wärtsilä® Gears Lips® Transverse Thrusters

The Wärtsilä gears have been designed to meet the highest standards of
operational efficiency, reliability, low noise and vibration. Wärtsilä delivers transverse thrusters for all different
kind of vessel types.
 Single input, single output
with
vertical and horizontal offset
; Controllable or Fixed Pitch Propeller
 Twin input, single output with
up to 3.8 m offset ; Robust and reliable design
; Easy installation
Integrated or separate
hydraulic system for gear and ; Low noise versions
CP propeller

© Wärtsilä
24 - Wärtsilä Marine © Wärtsilä
28 - Wärtsilä Marine
 S&AS Controllable Pitch Propellers Hydrodynamics
State-of-the-art Design
z Tailor-made designs
z Wärtsilä service concept and the „ Wake-adapted, high
world wide network of more than efficiency
5000 professionals „ Low noise and vibration level
in over 50 countries ensure the „ No cavitation erosion
„ Full scale references
best possible lifetime support.
z Design based on mission profile
„ Reduction of fuel
z International network of service consumption
and repair licensees z Match of propeller with engine
„ Increased reliability and
z Service portfolio comprises: lifetime
- training z CFD (Computational Fluid
- technical support Dynamics) calculations
- field service „ Design for full scale
- workshop and repair z Co-operation with marine model
- upgrading and modernisation test institutes
„ Independent and scientific
support

© Wärtsilä © Wärtsilä

Ship power development

Production Fixed Pitch Propellers
Power [kW]
Historical development of maximum power
applied per ship propulsor
70000

60000

50000

Fixed Pitch Propellers

40000

30000
Controllable
Pitch Propellers
Jets
20000

Podded
10000 Propulsors

0
1800 1820 1840 1860 1880 1900 1920 1940 1960 1980 2000 2020
Year

© Wärtsilä © Wärtsilä
 Today’s technical software challenges Vision on product structures & technical software

s
Change management

t em
WP - key customer/support processes/people

ys
o rS Hydrodynamic Mechanical
Manufacturing Sales Purchase Service

uls
Design Engineering

p E Processes

Pro
DG
LE
OW
ip KN

ersh ion CTIO

NS

ad vis FUN Integrated Product Data Structure

& Le te
)
(e NS
TIO
Knowledge, file and application manager Global-PDM
i si
ess lt LU
SO
in Mu CTS
s
Bu
U
OD
PR
SY
AS “Standard” Third party Special
PA
RT
S
Applications: Applications: Applications; MODELS
TECHNICAL DRAWING
SAP MSQ
S MATERIALS
NG DATABASE &
WI ACAD PUF WVINP-WVB CONFIGURATIONS
RA KNOWLEDGE DOCUMENT
SD UGS-PLM ANSYS DUCTPROP PROJECTS ARCHIVE
ENT MS-office VIEWCAST SPRESS REPORTS
UM ………. ………. ………..
OC
’ sD Product Information/Management Systems
M Business Tools
BO
… MSQ … BOM … EDM … INCLASS .. dig. ARCHIVE.. CAD ….. CAM … PDM … SAP

Projects/time/transformation Wärtsilä Propulsor Business

© Wärtsilä © 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.) Analyse dBase ERP

Applications/DATA CFD FEM IS&V

Fortran mechanical In process Simulation and Verification
applications part DNC BN
Fasys KS
description I-man
VR
web
Development & Buy Customer needs propeller
3D NX4TC2005
Database RA
BF
Knowledge Design-Engineering- Make
parameters
hydrodynamic
CAD-nominal
CAD-Blank
Resources
Models
CC
PM
Standard applications description CAD - Midtol Configurations BC
Manufacturing
Automation
Foundries & CAD-Manufacturing NC-Code FN
Third party applications
Special applications:
- Ufunc
2D CAD-Analyse Shopdocs CN
Machine shops Quaestor
CAD-shrinkage
CAM-data
- operations
- setup sheet printers
KC
.... ...hyd-mech-mfg plotters MK
Collaborative desktop-design & manufacturing - Ufunc CAD-Mastermodel-Associative-KDA-CAM - toollist
DW
- nc-listing extern HG
RS 6000
KG
AS 400 KX
Product Information/Management/Knowledge System PC LAN Resources methods UG-Manager
I-man
Appl. Tech.dB … MSQ … BOM … EDM … INCLASS . dig.ARCH... CAD … CAM … PDM … SAP
MSQ - Tools - Templates Automation
- NX1 = V8.1
- Operations - V15 = V5.0
- Fixtures - GRIP
- Programs
TC TC ? TC2MSQ TC TC TC TC TC TC TC TC2SAP TC - Machines - UFUNC
- Methods
- Controllers
- TCL
Team Center (metadata) ? - Feeds
- Speeds
- Wizards
- Proc. Assist.
- Cim source - shrinkage FTN

Knowledge based Engin. Knowledge Fusion Robots Management Production

Oracle (volume data)
Windows-XP
What HOW Data When-Where
© Wärtsilä © Wärtsilä
 TeamCenter data associativity & management NX, TC and SAP systems for WP-multi site

derived part/new part: links, copy, simlify, allowances, casting,block Design & Engineering Data Management (meta) Process Planning
•Reverse Eng. part
•Import eng. part 3D blank part
3D Blank part Assembly NX (CADCAM) TC (PDM) SAP (ERP)
Standard /
CAD
shopdocs: templates
SOLID part-info MM/PP Module
TC-ITEM
operation plan CAE As-engineered
eng. dataset:
set-up’s
• pdf associativity
libs. • workflow 3D eng. part 3D mfg. part-1 tool list Change
requests
• prt---------Æ general doc
CAM As-built
fixture/tools
As machined-1
blank or ipw
! toolpaths/NC
hod
met mfg. part-2 set-up-1 Shopdoc
Old part IS&V
Engineering NB
As machined-2 IPW Other (250) CS Module
NC mfg. WPNL-
Engineering S&AS

2D Drawing mfg. part-X set-up-2 applications

Shopdoc
libs. As-delivered As-maintained

engineering As machined-x
NC
IS&V

Shopdoc
set-up-X
IS&V

“no facetted model “

as-mfg.
part NC

set-up-as machined Shopdoc

Fortran
IS&V
Access Oracle (volume)
© Wärtsilä ENGINEERING MANUFACTURING © Wärtsilä

Wärtsilä propulsion multi site clusters WPNL example parts, processes and tools
Solid parts/processes:
WP Drunen NL WP Norway WP Wuxi China
• Workprep.Mfg. Progs. since 1960
• Manual CNC-programming since 1970
De
v • 2DCAD 1983, 3DCADCAM 1988
TC TC TC pro elop
duc
t • CADCAM-NX2 2004
ODS= Object LAN
Distr. Server
2 mbps 2 mbps ……
2 mbps WAN-infonet ……
….
.
WP Publication Ma
Server Work in Progress nuf
a
ass cture
em a
ble nd
WP Web

Free form parts/processes:

• Workprep.Mfg. Progs. since 1960
Released Data
• 3DCADCAM 1988
WEB clients • Workprep.Mfg. Progs. CADCAM 1988
WP Web Clients Viewing • CADCAM-NX2 2004

© Wärtsilä Info © 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
• Milling & grinding robots
Sliding block
• 5-axis simultaneous milling machine
Moving cylinder yoke
• Mobile measurement system, dedicated measuring machines
© Wärtsilä Hub body © Wärtsilä

Solid parts & milling-drilling- & turning machines at Wärtsilä TO-BE production chain example for blades (blade line)
Drunen
milling-grinding
NC-simulation robot-simulation
paths
Customer needs design geometry solidification
-simulation
Customer product

mould-
geometry
as-built information
Design/Engineering/MFG.
Integrated Product Data Structure
Knowledge,
Knowledge, file
file and
and application
application manager
manager
robot milling

photogrammetry mould assy and

pouring

manual grinding robot finish 5 axis simultaneous milling 2D machining

• Horizontal- & vertical(carrousel) lathe machines

• Machining centers, Milling machines, Drilling machines,
• Laser
© Wärtsilä cutting © Wärtsilä
 CPP-blade design & work preparation Robot grinding of EPS patterns

CAD blade model 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 Blade foot
Blade Robot 5 axes Portable
grinding machining
measuring grinding machining Measurement
BL- center KB-
BM-Mora RA-ABB center BF-Kolb PM-Solo
manual Skoda

Bolt-
line
© Wärtsilä © Wärtsilä
 Schematic overview CAD, CAM, PDM 3D CAD CAM, Product & Production set-up

PDM (database Teamcenter)

.doc
. DEF
CAD CAM Tool paths . TCL .NC PC PC
. VNC
postprocessor .VNC

postbuilder
interactive automated
template template
WH105-iTNC ASSY

shop data & docs

stand.func. User Cycle

© 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)

Vibration Oil
Envelope
spectra state

Accelerations
Decentralised
System 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) Manufacturing technology development projects (2)
Project: milling versus grinding Project: CAM-TC structures/data
Project: Hub component line (total machining)

Project: Meten=Weten
Project: shrinkage knowledge

Blade line
Machine shop

© Wärtsilä © Wärtsilä Bolt line

 Manufacturing technology developments projects (3) Thermal/flow solver & stress solver
Project: Casting design
Project: Reverse engineering

H04471 (1.1m2)

H04471 (1.1m2)
Project: Scanning of objects Project: Stress simulation

H04471 (1.1m2)

H04647 (13.4 m2)

© Wärtsilä © Wärtsilä

Continuous Improvement Summary WP technology development - focus

z Wärtsilä Propulsion focus points in development:

PL „ Hydrodynamics (supported by in-house Computational Fluid Dynamics

M (CFD) technology)
„ Continued efforts to improve efficiency, reduce emissions
ser
vi c „ Cavitation, noise and vibration
e&
mo „ Product innovation
nito
rin
g
„ Materials, casting technology and CAD/CAM/PLM technology
De „ in-house production, machine-shop/foundry, of strategic parts
v
pro elop
du „ product- and process innovation
ct

„ Mechanics and hydraulics

„ Product improvement and innovation
PL
M „ Mechatronics and control systems
„ Optimising in-service product performance
Ma „ Create added value by optimisation
nu
fa
ass cture
em a
b le n d „ Product line completion/extension
„ Follow the market pro-actively which ships and propulsion systems
are needed
© Wärtsilä © 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
andre.janssen@wartsila.com

© Wärtsilä