Project abstract

DockLaser aims to increase productivity, flexibility, quality and working conditions by developing laser processing techniques and equipment for the final assembly area in ship newbuilding and repair. These areas are characterised by low productive welding techniques with a high heat input, which leads to weld distortions and destruction of already applied painted and outfitted components. The project defines cases, requirements and goals for laser processing in dock area, to develop welding/cutting processes and equipment. Work safety and approval is focus of one work package. Close to reality tests and prototype production at the end-user sites will help to estimate the benefits and to achieve applicability under practical conditions.

The 3 main application areas are:

• welding of long linear fillet welds with tractor system,
• tack welding with mechanical system,
• manually guided welding/cutting for outfitting.

 

 

Project objectives   top

Laser processing techniques offer higher productivity and low heat input. Applications are to date limited to stationary systems in steel pre-manufacturing. DockLaser will develop mechanised mobile laser processing units for 3 typical application areas in shipbuilding:

• long linear structural welds
• tack welds
• cutting operations in outfitting.

Selected application areas cover the important joining tasks in the dock area. Savings of up to 50.000 man-hours are expected for a large cruise ship. Equipment manufacturers will develop marketable new products, applicable also for other industries.

The technical objectives of DockLaser are:

• develop reliable and stable processes for the 3 application areas,
• develop, integrate and test the moveable base station incl. the tools for the dedicated tasks,
• create guidelines and solutions for the qualification of the processes and safe operation of equipment,
• test and evaluate the equipment and processes under practical conditions.

 

 

Description of Work   top

The project will commence with a Requirements Definition Phase, containing a detailed survey of shipyard requirements, existing technical solutions as well as approval and work safety aspects. In the subsequent Development Phase (work packages 2 - 5) solutions for the three application areas (long linear welds, tack welds and outfitting) will be created. Work package 2 will focus on the process development under laboratory conditions, work package 3 will develop the components of the equipment following the concepts described before, work package 4 will integrate and test the equipment in the laboratories and work package 5 will put emphasis on approval and work safety. The final Evaluation Phase will shift the stage of actions to the end-user sites, where the equipment will be tested and evaluated under practical conditions. Each end-user is primarily in charge for one application area. Work package 7 will focus on dissemination with an Industrial UserGroup as the main tool. Work package 8 covers the technical and administrative management of this challenging project.
The work will be performed from a highly skilled consortium comprising 12 partners, from 5 EU countries, 1 associated country and 1 candidate state. The consortium includes 5 SMEs and is highly complementary, involving 3 end-users, 4 welding institutes, 1 major classification society and 4 equipment manufacturers. The group provides complementary and considerable experience in laser processing techniques. Practical feedback and dissemination is provided by an Industrial UserGroup. Project management is performed on the basis of long term experience in international R&D.