2024-02-09 07:30:20
After three years of work, a European project applied Industry 4.0 concepts in the shipbuilding sector in order to optimize production costs linked to the introduction of fiber reinforced polymers (FRP). Manufacturing processes have been automated thanks to the introduction of innovative digital technologies.
Fiber Reinforced Polymers (FRP) are composite materials offering a unique combination of light weight, high mechanical strength and durability. In the naval sector, they are traditionally used to build lightweight structures, up to 25 meters. Maritime regulations also authorize their use in the manufacture of larger vessels, up to 50 meters, however they are little used due to high production costs. A European project1 baptized FIBER4YARDS has just closed and aimed to optimize the use of PRF thanks to factory 4.0 concepts.
“Compared to traditional materials such as steel, fiber composites exhibit strong resistance to salt corrosion, giving them an extended lifespan in harsh marine environments, analyzes Julio Cesar de Luca, European technical coordinator at IRT Jules Verne. But the most important advantage is that they are much lighter, around 60%, and still have high rigidity and mechanical strength. This weight reduction helps reduce fuel consumption and therefore reduces the carbon footprint of ships. The use of these materials leads to a virtuous circle since the weight loss allows savings in other aspects, in particular using a less powerful engine or transporting more passengers. »
The construction of a 50-meter passenger transport catamaran was chosen as a study case to carry out this project. And to reduce the cost linked to the introduction of PRF, the main line of work consisted of digitalizing the manufacturing processes. For example, the resin infusion composite manufacturing technique, which involves penetrating the resin into the fiber structure, has been monitored and controlled in real time. To do this, sensors and cameras were installed to compare the manufacturing process with simulation models and the use of digital twins.
Gain production efficiency thanks to monitoring and instrumentation
This new manufacturing method has resulted in better control of this infusion technique by homogenizing the addition of the resin into the fiber. “Monitoring and instrumenting manufacturing processes makes it possible to do things right the first time and generate less waste, complete Julio Cesar de Luca. They also have the effect of going faster and therefore gaining production efficiency, that is to say spending less time for equivalent production. This digital optimization also leads to a gain in the quantity of raw materials used as well as the need for labor units. »
The teams on this project were able to take advantage of the possibilities offered by PRF to functionalize the parts. In partnership with the University of Le Mans, they developed Acoustic Black Holes (TNA) technology, also called ABH for Acoustic Black Holes, with the aim of reducing the ship’s vibration noise. A relief was added to the structure in order to trap the waves, without increasing its mass. Several parts functionalized with ABH technology and measuring approximately 1 meter² were thus manufactured and tests demonstrated a reduction in acoustic radiation of approximately 40%.
The project demonstrated that it is possible to reduce the weight of ships made of FRP by around 20% compared to those made of steel. The production cost linked to the use of these composites nevertheless remains higher than steel, but associated benefits must also be taken into consideration, as Julio Cesar de Luca points out: “From our case study, we show that reducing the weight of the vessel makes it possible to increase passenger transport capacity and reduce travel time by around 15%. This gain leads to a proportional reduction in fuel consumption as well as emissions of toxic gases (NOx: nitrogen oxide) and greenhouse effect (CO2). When we take the economic and environmental balance, we realize that it is possible to make composites competitive compared to steel thanks to the 4.0 tools developed as part of the FIBER4YARDS project. »
[1] The FIBER4YARDS project brought together 13 participants from 6 different countries: CIMNE (Spain); COMPASSIS (Spain); TSI (Spain); CW (Netherlands); NAVAL GROUP (France); INEGI (Portugal); IRURENA (Spain); TUL (Poland); 10XL (Netherlands); L-UP (France); Ateknea (Hungary); BUREAU VERITAS (France); IRT Jules Verne (France)
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