The document discusses automation technologies for shipbuilding processes. It describes how Kranendonk develops smart robotics and software to automate non-repetitive production tasks. This includes automated solutions for profile cutting, panel welding, and pipe assembly that improve productivity and reduce costs for shipyards. Kranendonk aims to integrate these automated processes and optimize material flow through facilities.

1. kranendonk is the robot technology centre
for non-repetitive production.
Improve your process
and productivity
Robotics for shipyard automation

2. Demand for technological innovations
Focus in shipbuilding shifts to qualitative
upgrading, rather than quantitative
expansion. New regulations and
requirements put pressure on shipyards
and their technological development.
To cope with these challenges, there is a
strong demand for technological know
how and innovative solutions.
Linking design and production
Innovations in the shape and functionality
of ships demand for technological
developments in shipbuilding. For
example, new hull designs require special
attention in assembly. The solution for
the production of complex designs is 3D
CAD. By linking the 3D CAD design and
the actual production with intelligent
software, highly accurate constructions
can be achieved.
Macro economical developments have a major impact on the
shipbuilding industry. Global powers are shifting and government
subsidies are influencing competition. New regulations are putting
pressure on yards. The industry is further influenced by innovations in
hull design and new vessel types.
Innovation brings
a new edge to
shipbuilding
Requiring complex
hull shapes to the
mm accurate
Facing our global challenges together
2 KRANENDONK Smart robotics

3. Early container ship (1956)
Full Cellular (1970)
Panamax (1980)
Panamax Max (1985)
Post Panamax (1988)
Post Panamax Plus (2000)
New Panamax (2014)
Triple E (2013)
Shipbuilders must keep up
To cope with the never ending search
for bigger vessels, shipyards are looking
for new ways in extreme engineering.
This puts a strain on construction. For
example, sections of the ship need to be
welded with high precision and all welds
have to be consistent. A perfect job for
robots.
Labour cost is the key determinant
Shipyards have to invest in their
production and are seeking ways to
reduce production costs. Labour cost
is a determining factor when it comes
to a yard's cost competitiveness. Also,
skilled labour becomes increasingly
hard to find. Thus, attention goes to
efficiency improvements in shipbuilding.
Automated production and robots
offer a solution for shipbuilders to stay
competitive.
Special purpose vessels demand
production flexibility
Shipyards are confronted with a demand
for new vessel types. Platform Supply
Vessels and related vessels types are
challenging ship designers. Shipyards are
combining skills to cope with the great
loads that these ships need to carry. The
production of these vessels comes with
new challenges and calls for a flexible
production environment.
A combination of
skills to meet
increasing demands
Getting bigger and
bigger: extreme loads
Improve
efficiency in
shipbuilding
3 Shipyard automation by kranendonk

4. Cutting edge innovation
The Robot Technology Centre
Smart robotics
Traditionally, industrial robots are used for
repetitive tasks. We develop sensors and software
that make our robots smarter. It means we can
automate non-repetitive production processes. This
unique competence opens a world of opportunities
for manufacturers. We use our skills to build fully
automated production shops, where all processes
are integrated and aligned.
Cutting edge technology
Our wide knowledge on robotic automation makes
us excellent problem solvers. We assist you from
an early stage, to create an optimal production
flow for your yard. This way, we jointly create a
tailored automation plan that raises productivity
and saves costs. The culture for innovation within
kranendonk makes sure we always deliver cutting
edge technology at the highest level.
25 Years of Making a Difference
For more than 25 years, kranendonk has modern-
ized shipyards at the highest level. Key milestones
have been:
1987: Delivery of the first robot for profile cutting.
1993: First robot welding system for web welding.
1996: The cutting robot gets integrated with other
processes, like cleaning and marking.
2000: Delivery of a total profile factory that cuts
over 3 km of profiles per day, all centrally controlled.
2003: Introduction of the intelligent RinasWeld
software, for 'hands-off robot programming'.
2005: Eight robots can jointly weld one panel, and
smartly distribute their tasks.
2010: Revolution in the pipe shop, by application of
robotics, storage and production control software.
2013: The Edge Preparation System offers a smart
way to comply to the IMO PSPC regulations.
KRANENDONK is the robot technology centre for non-
repetitive production. We make robot systems suitable
for non-repetitive tasks, by developing smart sensors and
software. kranendonk can maintain a Technology Centre
position by simultaneously being an engineer, supplier,
supporter and partner, and connecting to all stakeholders.
Supplier
Engineer
Technology
Centre
Supporter
Partner
4 KRANENDONK Smart robotics

5. ‘Being fanatic in robot engineering’
‘At kranendonk, we use clear methods
when designing new robot applications.
Whether it's a specialized welding tool
or a software interface, our way of work-
ing is characterized by an approach we
call Triple C. The first C is for Construction.
Creating a rigid construction that handles a
harsh production environment is the main
requirement. Secondly, Calibration makes
sure our systems are extremely accurate.
By applying software corrections, we make
a robot more accurate that it can physically
be. Lastly, Controls are being developed. We
use smart software to enable easy opera-
tion of the machines. In any new develop-
ment process, we pay attention to every
detail. You can call us fanatical about this.’
Evert Geurtsen
Technical manager
e.a.j.geurtsen@kranendonk.com

6. Shipbuilding is all about
production flow
Welding of assemblies is a
perfect job for robots
Automating key parts in the process chain
In shipbuilding, it is all about the production flow.
Processes have to be aligned as raw steel plates are
turned into giant vessels. The challenge is to keep
the flow running, while maintaining a tight grip on
building quality.
The shipbuilding process is one of the most complex
construction jobs created by man. All production
processes that run separately have their respected
challenges. Since 1987, kranendonk is the leading
technology supplier for advanced robotics in
shipbuilding. We offer advanced robotic systems to
automate key parts in the process chain.
In the process we focus on:
Profile and cutting shops (step 2) By linking all sys-
tems, we improve your flow and realize large cost
savings. Smart storage and just-in-time delivery cre-
ates an effective cutting shop.
Assembly and welding shops (step 3) Welding of webs,
panels and 3D sections is a perfect job for robots.
Controlling them is the challenge, so we focus on data
flow and intelligent software tools. It saves manual
welding and improves production quality.
Pipe shop (step 5) By robotizing the pipe shop, the
production time for each pipe goes from hours to
minutes. Major cost savings are realized by our inte-
grated solution.
2 Cutting shops
Profile Processing (page 10)
Edge Preparation System (page 11)
4 Section assembly
Joining of sub-assemblies
3 Assembly and welding shops
Double Hull Welding (page 12)
Panel Welding (page 12)
Web Welding (page 12)
6 KRANENDONK Smart robotics

7. Total profile processing
solutions
‘Keeping your flow running’
‘As customer support manager, it is my
goal to maintain the highest possible
productivity of your kranendonk equip-
ment. We offer a full pack of services to do
so. Our support engineers regularly visit
your yard for inspections and performance
tests. This way, we keep you productivity
high and reduce downtime to a minimum.
Also, we train your operators and mainte-
nance crew. In this way, we improve your
flow and keep it running.’
Werner Smeitink
Manager Customer Support
Helpdesk
Holland +31 344 655 443
Japan +81 832 425 444
support@kranendonk.com
Major cost savings by robotizing
the pipe shop
Edge Preparation System
to comply with IMO PSPC
5 Pipe Shop
Robotic pipe shop (page 14)
6 Module outfitting
Prepared tubes are mounted
7 Ship assembly
At the dock
1 Input raw materials
Steel plates and profiles
7 Shipyard automation by kranendonk

8. Setting the right course for the future
Exploration of deepwater oil fields is
increasingly economically viable. It results
in more operations in remote areas. The
Seven Oceans has been developed to
perform pipe laying operations in these
areas, where conditions are tough. Despite
its compact design, the vessel has a high
payload and excellent seakeeping charac-
teristics. IHC Merwede shipyard – a long
term customer of kranendonk – launched
the Seven Oceans in 2010.
Photo courtesy IHC Merwede
8 KRANENDONK Smart robotics

9. 9 Shipyard automation by kranendonk

10. Integrating logistics for the perfect flow
Integrating the logistics around profile processing
increases productivity and flow. A fully equipped
plant features a range of components: cutting cells,
logistical equipment and dedicated production soft-
ware. We deliver all software and hardware to build
such a shop, realizing just-in-time production.
The cutting lines can be equipped with roller con-
veyors and infeed and outfeed buffers for tempo-
rary profile storage. Additionally, high-rise storage
systems can be placed before and after the system.
This results in an optimal production flow.
Highest quality components
A key component in the profile processing shop is
the CCS 600 cutting cell. The cutting cell is based
on our standardized ccs concept. All electrical and
measuring components are integrated into the rigid
base frame, resulting in a durable cutting system
that withstands a harsh shipbuilding environment.
The production software adapts the cutting path to
the actual dimension of each profile, so the highest
accuracy is achieved. By setting up a direct CAD
interface, your work preparation time is reduced to
almost zero.
Efficient profile processing is important for a shipyard.
The focus should be on creating a perfect flow, where
all machines are synchronized with planning and stock.
kranendonk connects all machines into one solution.
High speed plasma cutting for
increased throughput
All operations (e.g. cutting,
marking, grinding) in the cutting cell
Profile cutting line with infeed storage
Maximizing flow by
integrating all processes
Complete solutions for profile processing
10 KRANENDONK Smart robotics

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'We maximize your output by realizing a
perfect production flow'
‘Over the past 30 years we have delivered
dozens of profile cutting lines to shipyards
all over the world. Our success is based on
the competence to integrate all related
processes into one complete solution that
is centrally controlled. It means that one
man runs a complete profile cutting shop.
The most advanced profile shops can cut
more than 3 km of profiles per day. With
these advanced systems, you can save
heavily on labour costs and maximize your
output per square meter of shopfloor.’
Jelle Janssen
Sales manager
j.c.a.janssen@kranendonk.com
Milling a constant radius
To improve the quality of coatings in shipbuilding,
IMO PSPC demands the preparation (rounding) of
plate edges. Automation of this process requires
an adaptive machine that perfectly follows plate
contours. The Edge Preparation System combines
proven CNC technology with a state-of-the-art force
controlled milling system. The system machines
both sides without turning of the plate. Advanced
software with a touch interface makes sure that
­
operation is easy.
Edge Preparation System
Adaptive milling technology:
constant force around contours
Software to control the production flow
The kranendonk production software takes care
of a continuous production flow, controlling the
logistics as well as additional machines.
IMO PSPC compliant edge preparation
11 Shipyard automation by kranendonk

12. Challenges in construction
Ship panels, webs and block sections demand
consistent and high precision welding. These sub-
assemblies are one-of-a-kind operations with many
hard-to-reach spots. kranendonk's welding robots
can reach these difficult places and make optimal
use of the available space, with no collisions.
Automation for 'one-offs'
Welding in shipbuilding is non-repetitive, mean-
ing that the programming has to be automated.
kranendonk offers a software solution called
RinasWeld, which is the most advanced production
tool for welding robots available. Also, we offer easy
to use shopfloor interfaces for direct data entry.
Robotic panel and web welding
Whether it is about large panels, micro panels or
webs, kranendonk's travelling gantries offer the
most flexible solution. Our panel and web wel-
ding systems support one, two or four robots. The
robots simultaneously weld and smartly distribute
tasks between them. The rigid design of the gantries
ensures extreme stability and high quality welding.
Double hull welding with tiny robots
Welding the double hull of a ship is difficult because
of the limited space. Our Double Hull Welding
Gantry performs automated robot welding of these
sections. Tiny robots on extendable sticks can
manoeuvre into the smallest spaces of the blocks.
Coping with the complexity
of designs
‘Hands-off’ robotic welding solutions
Eight robots automatically
working together
Welding in shipyards comes with specific challenges to
cope with the complexity of the designs. Kranendonk’s
robot welding solutions can handle continuously changing
designs, by using advanced software tools.
1st price: Maritime Innovation Award for our
Panel Welding Gantry with RinasWeld software
12 KRANENDONK Smart robotics

13. Panel Welding Gantry
Direct data entry at the shopfloor
Direct data entry gives the operator the ability to
control the system by entering parameters. This
way, the operator does not require knowledge
about robot programming. It makes operation easy.
Depending on the complexity of the products, the
robots can be programmed by direct data entry at
the shopfloor, or by importing of 3D CAD models.
We have the most flexible solution for your yard.
The sophisticated RinasWeld software
For complex assemblies, kranendonk offers the
world's most sophisticated robot programming soft-
ware: RinasWeld. This software prepares the pro-
duction tasks in the office, by using 3D CAD data of
the product. RinasWeld gives maximum flexibility,
as all programming tasks are performed automati-
cally. RinasWeld balances the work load between
multiple robots to maximize productivity.
Easy shopfloor control with touch interface
The software generates collision free robot paths
Double Hull Welding Gantry
Web Welding Gantry
Small robots reach inside
double hull sections
13 Shipyard automation by kranendonk

14. A unique automation solution for shipyards
The production of pipe spools is a true craftsman's
job. Flanges have to be welded to the tubes within
strict tolerances. The process is hard to automate,
but we offer a unique solution that does the job. All
processes are integrated and centrally controlled, to
create the first robotic pipe shop in the world.
From 4 hours to 8 minutes production time
The robotic pipe shop is the result of a thorough
analysis of the production of pipe spools in the ship-
building industry. The robotized pipe shop brings
the production time for a pipe spool back from
4 hours to 8 minutes. The central control system
takes care of the production flow and monitors
each tube individually.
Fully automated from infeed to bending
The pipes go from the storage through a sawing
machine. After sawing, rest material is fed back into
the storage. Next, the pipe is grinded, to maximize
welding quality. Four robots mount and weld the
flanges to the pipes. Then, the pipes are ready to go
to the bending lines. Bending of the pipes is done
with the flanges attached. All these steps make
sure that the pipe shop reaches high capacity and
quality.
Capturing craftsmanship in
the future pipe shop
The robotic pipe shop
Accurate flange assembly and welding
To the bending lines
14 KRANENDONK Smart robotics

15. 'We revolutionize the pipe shop'
'Manufacturing pipe spools is a skilful job.
Welders are trained to mount the flanges
within tight tolerances. We found that
it is truly a craftsman's job, which made
it challenging to automate. During the
development of the robotic pipe shop,
key parts of the flow were changed. Now,
the flanges are mounted before the tubes
are bent. When we installed the first
robotic pipe shop, we used the welder's
knowledge to fine-tune the system. Their
craftsmanship has been translated into a
smart robot system, that revolutionizes
the traditional pipe shop.'
Richard Polder
Project manager
j.h.polder@kranendonk.com
All tube sizes in any order, give
flexible production
Fully automated logistics with
intermediate output
Smart storage system with sideways infeed
and waste reduction functionality
15 Shipyard automation by kranendonk

16. Kranendonk is the robot technology centre for
non-repetitive production. By implementing intelli-
gent robot technology, we enable manufacturers to
produce more efficiently and effectively. We supply
custom build solutions that are cleverly integrated
into material and data flows.
Kranendonk was founded in 1983. We started
our company as a supplier of custom automation
systems for industrial applications. Over the years
we have specialized in advanced robotics for heavy
steel applications. Today we offer an innovative
approach that creates a range of automation oppor-
tunities for manufacturing companies.
In the near future we see technological and macro-
economical developments putting pressure on
the production process. Advanced automation is
spreading into new areas. Integrated process and
centralised operations are decisive factors in choos-
ing the right equipment. Kranendonk will keep
assisting companies in transforming their produc-
tion processes to make them more efficient, flexible
and ready for the future.
www.kranendonk.com
Contact information
Kranendonk Production Systems bv
(headquarters)
Phone +31 344 623 944
Fax +31 344 623 388
P.O. Box 6147
NL-4000 HC Tiel
The Netherlands
info@kranendonk.com
www.kranendonk.com
kranendonk
Sir Rowland Hillstraat 10
NL-4004 JT Tiel
The Netherlands
v 07 2013