© 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

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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……….

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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:

• pdf

• 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

andre.janssen@wartsila.com