04.10.25 shipyard welding_cutting final

7/28/2019 04.10.25 Shipyard Welding_Cutting Final

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Bertil Pekkari November 2004

Shipyard panel lines for

welding and cutting

by

Bertil Pekkari

[email protected]


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Order book for shipyards in September 2004

Order book is corresponding 3 years work load

South Korea

38,4 %

Japan 34,3%

P.R.China15,7%

Rest of the

world 4,2 %

Denmark1,1% India 0,1 %

Germany1,6%

Poland1,2%

Taiwan 1,7%

Croatia1,7%


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B Pekkari, 2001-08-14

Weld Metal Depos ited 1976-2002

MMA MIG/MAG FCW SAW

USA

348 000 tonnes

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

19

76

19

78

19

80

19

82

19

84

19

86

19

88

19

90

19

92

19

94

19

96

19

98

20

00

20

02

16 000 or 5

67 000

19 %

204 00059 %

60 000

17 %

Japan

240 000 tonnes

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

1976

1978

1980

1982

1984

1986

1988

1990

1992

1994

1996

1998

2000

2002

13 000 or 5 %

64 000

27 %

127 000

53 %

36 000

15 %

245,000

Wes tern Europe

401 000 tonnes

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

19

76

19

78

19

80

19

82

19

84

19

86

19

88

19

90

19

92

19

94

19

96

19

98

20

00

20

02

294 000

74 %

49 000

12 %

34 000 or 8 %

23 000 or 6 %

Decrease MMA 5-8 %/year in Europe


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Shipyard production lines

Flat panel production lines

Bulkhead production lines

Double bottom assembly lines

Curved panel production lines Mini-panel production lines

Micro-(Web)panel production lines

(Profile cutting lines)(Combi lines for cutting & welding)


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Flat panel production lines

Volume production

Panel size range normally 10x12 m 16x21 m

Consisting of:

edge preparation station

one-side-welding station - with conveyors

panel rotation station

cutting, shot blasting/grinding & marking station

stiffener assembly

stiffener welding

transport conveyors

load out station


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Panel line


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Edge bevelling stations

Good edge preparation is essential for goodwelding results in OSW-stations

Light duty milling up to 40 mm plate thickness

Special tooling for I - X & Y-joint forms

Clamping with vacuum

Milling speeds up to 2m/min

Straightness 0,25 mm

Possible to integrate in welding line


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Milling tool for joint preparation


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OSW-stations

Effective & quality butt welding of plates

carbon & stainless steel

Material handling & flexible transportation important

infeed conveyors (2-4 pcs) with hydraulic clamping;

sideways aligning of plates

outfeed conveyors with hydraulic or vacuum clamping

Alternative plate clamping methodshydraulic traditional

vacuum prefered new system, advantages:

open space for control of welding

different plate thicknesses can be welded together

high clamping force 6000 kg/m

no big foundation needed

magnetic not used, disadvantages

healthy risks

disturbance of welding process


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OSW-stations

Welding equipment:

LAE/TAE (SAW) DC/AC 1600A, 1250A Twin wire SAW

Weldpress -pressure rollers in front of the welding heads quarantee: levelled joint

controlled heat distortion

secured clamping against flux backing

Seam tracking

GMD-electro mechanical

laser

Future methods laser

combined MIG/Laser

friction stir welding (aluminium)


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Stiffener assembly stations

Different degree of automation possible:

manual assembly & manual tacking

mechanized assembly & manual tacking

mechanized assembly & automatic tacking

Mechanized assembly, features:

stiffeners prepositioned on casset racks

positioning possible 0-90 -rotating beam

straight profile position

prebending of panel possible in stationary stations

Automatic tack-welding, features:

normally tacking on one-side only

PLC-controlled welding trolley movement

vacuum/magnetic clamping


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Stiffener welding stations

Stationary or movable portals

Depending on capacity demand 1-4 (or more)

welding trolleys

Welding methods SAW, MIG/MAG, (Tandem/Twin)

PLC or CNC-controlled welding

intermittend, staggered & chain intermittend welds

possible even with SAW

Prebending possible with vacuum/magnets

Welding possible in all angles (0-90)


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Welding gantry with one welding head


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Fillet MIG/MAG welding heads


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Fillet welding head suspended on

movable gantry


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Plate/panel transportations

Flexible transport system is for through put as

important as efficient welding Optional systems:

chain conveyor with manual hook

- traditional & economical

conveyor with hydraulic clamping

- precise & efficient

- straight transport of panels

- secure clamping

UHL-trains with low lifting

UHLL-trains with high lifting

- replaces also load out stations


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Double bottom assembly lines

Different degree of automation

Flexible transport connection with flat panel line

important

Web mounting gantry

- mechanized assembly, manual tack-welding Vertical welding gantry

- automated welding of vertical seams

Robotized welding gantry- robotized welding of vertical/horizontal seams

UHL/UHLL-transportation


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Vertical welding stations

Welds four (4) vertical welds of double bottom cross-

section simultaneously

Replaces 8-10 manual welders (or two robots)

Main features:

water cooled 500A -welding equipment PLC-programmed operating menu, operator friendly

on-line adjustment of welding parameters (V, A, speed)

freely programmable oscillation jumps over horizontal

stiffeners motorized rotation of welding heads 45

control from plattform & from egg-box


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PEMA VWS -vertical welding

equipment, 4x 500A torches


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Practical example of capacity calculations

Object:

double bottom construction, according to enclosed sketch

nr of cross-sections: 15 pcs

nr of vertical seams: 50 pcs

total welding length: 150 m

throat thickness: a = 7 mm

Welding equipment:

PEMA VWS -vertical welding equipment, 4x 500A torches

LAW 510

positioning with laser-light - cross beam programmable veawing / welding length / parameters


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Practical example - VWS

Manual welding:

nr of welders: 4 pcs welding speed: 10 cm/min

effective welding time/shift: 4 hours/8 hours

total manufacturing time: 12,5 hours/each welder

Automatic welding: nr of welders: 1 pcs

nr of torches: 4 pcs

welding speed: 15 cm/min

effective welding time/shift: 6 hours/8 hours

total manufacturing time: 5,5 hours

+ quality

+ working conditions


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Practical example - VWS

Payback time analysis:

* 4 welders each 12,5 h= 50 hours

* 1 welder with VWS = 5,5 hours

--> VWS replaces 9 welders

--> 20,- Euro/ h x 9= 180,- /hour

--> average 2000 hours/ shift/year= 360.000 Euro/a

* Payback time in one shift operation= approx.1 year


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Micro-web production lines

Flexibility to produce webs from 1-6 m of width and

1-16 m of length Separate pallets with locking hooks for small webs

(< 3 m width x < 8 m length)

Flexible mounting gantry for stiffeners

assembly beam rotates 0-90

manual and automatic tack-welding

Stiffener welding portal with 2 MIG-welding heads

welding heads rotates 0-90

additional prebending station

Tandem/Twin MIG welding optional

Robotized welding possible to integrate to this line


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Curved panel production

Different end-products-different needs for automation

Cruise-ships, ferries- many decks /few small curvedsections

Container ships, tankers- many large shaped sections

Different building methods

transversal framing

longitudinal framing

mixed framing

Optional manufacturing methods line -production with movable pin jig platforms

stationary production platforms/cells


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Stationary manufacturing cell

fixed pin jig platforms- movable assembly &weldinggantries

Production steps

all stages of work on one station

bended plates lifted on pin jigs- fixed &tack-welded

butt welding - semiautomatic or automatic

A6 -(SAW) tractor , backing bar with magnets.

Optionally tilting jig welding gantry with SAW or MIG equipment

automatic sensing tilting angle



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Pin jig platform for panels


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Assembly of stiffeners & curved frames

movable gantry with rotating assembly beam hydraulic /magnetic clamping

magnets for pulling the panel against frames

Welding of fillet-welds - manual or automatic

two individual welding heads

special seam tracking system- automatic

sensing of height and inclination

PLC-control of welding parameters

oscillation (and jump over)


CC


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Finalization of welding & assembly with jig cranes

or service gantries with semiautomatic welding equipment

special tools for fitting

special welding automatons for welding

Robotized welding

applicable for curved section welding

complex programming of welding

only a few functioning systems in Europe Lind-yard in Odense-DK, Fincantieri



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C d l d ti


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Line production system

more efficient than stationary movable pin jig platforms and welding gantries

optional tilting tables for mechanization of butt- welding

Production steps

different stages of work on different stations

plate assembly and tack-welding-> platform moved

butt welding - semiautomatic or automatic ->p.m.

stiffener assembly and tacking-> p.m. stiffener welding ->p.m

finalization on several stations-> platform returned


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Pin jig platform for curved panel


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Robotized welding of panels

For welding of

subassemblies with simple geometry

stiffeners/ girders on panels

Different programming methods vision based on-line programming

welding macros

off -line by nesting with main design software

f S


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Robot system

Cell controller software &

Machine vision

Track motion up-to 60 m

CASE: Machine vision guided welding system

Working range : 60 m x 5 m x 1 m

Free workpiece positions

Vision system for Shipyards

Vi i f Shi d


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Vision system is used to scan and analyse workpiece

No CAD information required

Cross-sections of the t-bars are measured automatically


Vi i t f Shi d


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Bulkhead robot gantry

PEMA b t ldi t


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PEMA- robot welding gantry

Ship panels 20x20 m welded with the hybrid laser


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Ship panels 20x20 m welded with the hybrid laser

MIG process

4 CO2-laser 12 kW


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YAG-laser installation(SHIPYAG planned EU-Project)

Potential participants:

Meyer Shipyard Germany

HDW Shipyard Germany

Chantier de lAtlantique France

ESAB

Det Norska Veritas Norway

Astilleros Shipyard Spain

Odense Shipyard Denmark

Ficantieri Shipyard Italy

Research centres in the

Netherlands, Italy, Germany etc

04.10.25 shipyard welding_cutting final

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