Transcript
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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.
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Transition of production and number of
employees
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Transition of productivity and
mechanized welding ratio.
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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.
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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
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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)
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2. A few examples of production systems
in Japanese shipyards
2. 1 IHI Kure shipyard
2. 2 SHI Yokosuka shipyard
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Process flow of unit-panel and slit
process (IHI)
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Longitudinal setting equipment (IHI)
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Unit-panel assembly equipment (IHI)
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Unit-panel straightening equipment (IHI)
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High speed FCB ( Flux Copper Backing)
one-side welding equipment (IHI)
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Trans. web inserting equipment
(IHI)
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Welding robots (IHI)
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Welding robot configuration (IHI)
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Welding joint for robots (IHI)
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Comparison of assembly processes
for flat hull block
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Assembly method of double hulls block
in Yokosuka Shipyard (SHI)
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Layout of single panel line (SHI)
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Layout of complex panel line (SHI)
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Numerical-controlled welding robot for
sub-assembly (SHI)
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Longitudinal welding equipment (SHI)
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Self-moving reformer (SHI)
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Fillet welding robot for slot (SHI)
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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.
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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
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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
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CAM System
• CAM System (Off Line Programming)
Robot motion data generation system.Data conversion system.
Robot simulation system.
Data transferring system.
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General view of the welding
robot equipment (KHI)
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General view of multi-robot system
(NKK)
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Welding robot of sub-assembly
(Hitachi Zosen)
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A typical work piece (KHI)
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This is also typical work of NKK.
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Typical CAD/CAM System (NKK)
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Task assignment method
for each robot (KHI)
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Graphical display for the robot simulator
(KHI)
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Method of sensing a
bead connecting point (KHI)
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Appearance of welding bead
at a corner of inclined-joint (KHI)
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General view of panel sub-assembly line
(NKK)
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Schematic diagram of multi-robot
welding system (NKK)
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Configuration of welding robot (NKK)
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Example of panel nesting (NKK)
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Example of robot simulation (NKK)
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Line management system (NKK)
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Corner sensing by high frequency
rotating arc process (NKK)
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Cornering bead appearance with arc
sensor joint end detection (NKK)
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Bead appearance with high speed
rotating arc sensor (NKK)
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Appearance of bead connection section
with bead end detection (NKK)
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A concept of CIM
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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.
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High speed welding by high frequency
rotating-arc (NKK)
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Macro structure of rotating arc welding
(NKK)
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High speed welding by tandem process
(IHI)
• Conditions under which an
undercutting occurs.
X s< X m
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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
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Mechanized ratio of various work
in current Japanese shipyard
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Fitting equipment (SHI)
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Automation of plate bending process by
line heating(IHI)
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Welding robot for curved block one-side
welding (Hitachi Zosen)
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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.
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