Japan Shipbuilding

8/6/2019 Japan Shipbuilding

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Contents

1. Background: Problems and issues which Japaneseshipyards have faced.

2. A few examples of production systems inJapanese shipyards.

3. Application technologies of robot weldingsystems. (CAD/CAM Systems, Cell Control of

multi-robots, Computer Integrated Manufacturing)4. High speed welding technology.

5. Application of automation for additional work.

6. Conclusions and present / future issues.



Transition of production and number of

employees



Transition of productivity and

mechanized welding ratio.



Background: Problems1. Sharp drop in demand of new shipbuilding after

the oil shock of 1973.

2. Decrease in number of employees. (Earlyretirement plan, shift employees to the otherdepartments.)

3. Young generation tends to avoid manufacturing.(Dirty, Dangerous, Distressing)

4. Highly educated workers expect high salaries.

5. Current workers are getting advanced in age.

6. Intensified cost competition globally.



1.Decreasing costs

2.Improving and stabilizing quality.3.High productivity and high efficiency.

4.Moving away from high level skill and

experience.

5.Transforming a labor intensive industry to

an intellectual industry.

Background: Issues to survive



Background: Current trends

1. Resurgence of new shipbuilding demand.

2. Increase of work volume in double hull tanker.

3. Automation in production systems expands

rapidly.

4. Growing improvement of computer technology.

5. Studying ultra-modernized production systemdeveloped by The Shipbuilders’ Association of

Japan (’82~’86)



2. A few examples of production systems

in Japanese shipyards

2. 1 IHI Kure shipyard

2. 2 SHI Yokosuka shipyard



Process flow of unit-panel and slit

process (IHI)



Longitudinal setting equipment (IHI)



Unit-panel assembly equipment (IHI)



Unit-panel straightening equipment (IHI)



High speed FCB ( Flux Copper Backing)

one-side welding equipment (IHI)



Trans. web inserting equipment

(IHI)



Welding robots (IHI)



Welding robot configuration (IHI)



Welding joint for robots (IHI)



Comparison of assembly processes

for flat hull block



Assembly method of double hulls block

in Yokosuka Shipyard (SHI)



Layout of single panel line (SHI)



Layout of complex panel line (SHI)



Numerical-controlled welding robot for

sub-assembly (SHI)



Longitudinal welding equipment (SHI)



Self-moving reformer (SHI)



Fillet welding robot for slot (SHI)



Summary

2. A few examples of production systems

1.Optimize production ratio.

* Standardize the design.

*Simplify the design.

*Simplify the production process.

*Automated production of small steps.

*Result is accuracy and quality.

2. To automate production system.

*Chose the equipment to match the process.

*High speed welding is required.



3. Application technologies of

robot welding systems1. CAD

2. CAM System (Off Line Programming)

Cell Control of Multi-Robots

Simulation

Sensors

3. Computer Integrated Manufacturing



CAD• 3D CAD System based on product model

Each shipyard has developed their own CAD system aimed

not only for drafting but also out-putting information formanufacturing.

Linked with welding robot:

Welding data

Welding process

Material

Welding position

Welding edge configuration



CAM System

• CAM System (Off Line Programming)

Robot motion data generation system.Data conversion system.

Robot simulation system.

Data transferring system.



General view of the welding

robot equipment (KHI)



General view of multi-robot system

(NKK)



Welding robot of sub-assembly

(Hitachi Zosen)



A typical work piece (KHI)



This is also typical work of NKK.



Typical CAD/CAM System (NKK)



Task assignment method

for each robot (KHI)



Graphical display for the robot simulator

(KHI)



Method of sensing a

bead connecting point (KHI)



Appearance of welding bead

at a corner of inclined-joint (KHI)



General view of panel sub-assembly line

(NKK)



Schematic diagram of multi-robot

welding system (NKK)



Configuration of welding robot (NKK)



Example of panel nesting (NKK)



Example of robot simulation (NKK)



Line management system (NKK)



Corner sensing by high frequency

rotating arc process (NKK)



Cornering bead appearance with arc

sensor joint end detection (NKK)



Bead appearance with high speed

rotating arc sensor (NKK)



Appearance of bead connection section

with bead end detection (NKK)



A concept of CIM



Summary of

3. Application technologies of robotwelding systems

• OLP is indispensable to practical application of

robots and it has progressed widely. Automationof OLP is very desirable

• Cell Control in multi-robots welding system isapplied successfully for equalization of jobassignment and avoiding interference.

• Management information system is important foroptimizing the productivity.



High speed welding by high frequency

rotating-arc (NKK)



Macro structure of rotating arc welding

(NKK)



High speed welding by tandem process

(IHI)

• Conditions under which an

undercutting occurs.

X s< X m



5. Application of automation for

additional work

• Automated Fitting equipment

• Automation of plate bending process

• Automated one-side welding of curved

block

• Painting robot in double hull structure



Mechanized ratio of various work

in current Japanese shipyard



Fitting equipment (SHI)



Automation of plate bending process by

line heating(IHI)



Welding robot for curved block one-side

welding (Hitachi Zosen)



6. Conclusions and present / future issues

Present / Future Issues

• Automation or mechanized processes

should be advanced for fitting and painting

jobs.• Product managing systems which supports

total business and production activities is

desired in future.

Japan Shipbuilding

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